A. INSIDE BUS 10. Dome & Stepwell Lights Inspection Procedures

A. INSIDE BUS 10. Dome & Stepwell Lights

Inspection Procedures: Repair (or note) if: Out of Service if:

Dome and Stepwell Lights

Check passenger compartment dome lights Any lens is cracked, broken, or dirty (repair). Any lens is broken or missing and light bulb and driver’s compartment dome lights (if or fixture is exposed. equipped) for condition and operation.

Any single dome light is not working (repair). Two or more passenger dome lights are not working.

Dome light switch is loosely mounted or rocker/knob is missing (repair).

Check stepwell lights for condition and Stepwell light is on when door is closed Stepwell light is not functioning. operation. (repair).

Stepwell light does not activate, when clearance lights are on and the service entrance door is open; or the stepwell light does not work according to Florida School Bus Specifications.

Check driver’s compartment dome lights (if Either driver’s compartment dome light does equipped) for condition and operation not function. (starting September 1995).

39 2008

A. INSIDE BUS Service Door

11. Inspection Procedures: Repair (or note) if: Out of Service if:

a. Operation

Check service door assembly for operation, Door does not seal properly or seals are Door jams, binds, or will not open a minimum adjustment, condition, mounting, and fit. damaged, ripped, or deteriorated (repair). of 24 inches, or requires more than 25 lbs. of

effort to open or close door.

Glass has been replaced with plexiglass, is broken, or is cracked.

Door glass is fogged more than one (1) inch in from border, or visibility through glass is poor.

Door is equipped with a locking system that is not OEM factory approved.

Door assembly is damaged, or mounting is loose.

Door seals are not present.

Door will not open or close completely.

Door control doesn’t move freely (repair). Door does not operate (open and close) properly.

Door operation requires excessive force (Continued on Next Page) (more than 25 lbs. of effort).

40 2008

A. INSIDE BUS Service Door


b. Control

1) Check manual service door control Control, rod hardware, or mounting is loose and rod assembly for over-center or (repair). latching device, condition, and mounting. Door control handle stops are not correctly Manual control will not lock over-center, or

adjusted. latching mechanism is inoperative.

2) Check air or vacuum powered service Air or vacuum powered system leaks or Air or vacuum door emergency release does door control assembly for leaks, needs adjustment (repair). not function, or control is broken. operation, insecure door in closed position, and emergency release. Air or vacuum door opens or closes at an

excessive rate or opens too slowly.

Air or vacuum door does not operate (open and close) properly or is insecure in the closed position.

c. Overhead Pad

Check bus for pad that is a minimum three (3) Pad is loose, or cover has minor rip(s) Pad is missing or cover is severely ripped, inches wide, high density foam rubber (repair). exposing foam. padded safety cushion, mounted directly above the inside of the service door.

41 2008

A. INSIDE BUS 12. Horns

Inspection Procedures:

Horn(s)

Check for operation of both horns and for location and condition of horn switch.

Repair (or note) if: Out of Service if:

Either horn is inoperative.

Horns are not audible at 500 feet.

Horn button is not mounted in OEM location.

Horn button sticks, or horn button operates intermittently such as when steering wheel is rotated.

42 2008

A. INSIDE BUS 13. Mirror Adjustment, Condition


a. Rearview

Check exterior rearview mirrors specifications, condition, mounting, adjustment.

for and

Repair (or note) if:

Electrically controlled mirror is not operating properly (if applicable).

Out of Service if:

Any required rearview mirror is not present.

Any mirror is cracked, broken, or loose in its frame.

Either mirror is out of adjustment (does not give driver a clear view down to lower outside edge of rear tire at ground level, on both sides to the rear).

Any mirror reflective surface is deteriorated.

Any portion of mirror mounting system is loose, missing, or broken.

Any mirror does not meet applicable specifications.

(Continued on Next Page)

43 2008



b. Convex

Check convex crosswalk and side-view mirrors for specifications (correct type, size, and location) condition, mounting, and adjustment.

NOTE: “No blind-spot” mirror system meeting new performance specifications is required starting November 1990 (e.g., Bus Boy-type).

Electrically controlled mirror is not operating properly (if applicable).


Any required convex mirror is not present.

Any mirror is cracked, broken, or loose in its frame.

Any mirror reflective surface is deteriorated.

Any portion of mirror mounting system is loose, missing, or broken.

Any mirror does not meet applicable specifications.

"No blind-spot" convex crosswalk mirrors do not provide driver with indirect vision (of the area at ground level) from the front bumper forward, and the entire width of the bus, to a point where the driver can see by direct vision.

44 2008



c. Interior

Check interior rearview mirror for condition, and mounting.

size,


Convex mirror system does not provide driver with indirect vision of the area (at ground level) around the left and right front corners of the bus to include the tires and service entrance, on all types of buses, to a point where it overlaps with the rear vision mirror system.

Interior rearview mirror is not at least 6” x 30” (except Type A1, which shall be a minimum of 50 square inches).

Mirror does not have rounded corners and protected edges.

Any portion of reflective surface is obstructed by stickers or other items or is deteriorated.

Driver’s view of images in mirror is not clear due to distortion or other causes.

Mirror or mounting system is loose.

45 2008

A. INSIDE BUS 14. Driver’s Seat and Belt


Driver’s Seat and Belt

Check driver’s seat and belt for specifications Seat adjustment binds or is difficult to operate Driver’s seat (non-air type) will not adjust four (type and adjustability), condition, mounting, (repair). (4) inches fore and aft, four (4) inches up and and operation. Air suspension seat required down, or back will not tilt (except Type A shall on all air brake equipped buses starting Seat adjustment is loose or adjustment be manufacturer’s standard). September 1995. hardware is missing (repair).

For new buses manufactured starting 2009, Seat upholstery or foam is deteriorated or Wrong type of seat is installed (high back driver’s seat belt webbing is to be bright damaged (repair). seat with cloth insert required starting with orange or lime green in color. Revised 1989 Specifications).

Seat bottom is loose in frame or Seat mounting is unstable, loose at floor, or mispositioned (repair). seat mounting hardware is missing.

Seat frame is exposed due to deterioration of Driver’s seat belt is missing or of wrong type; upholstery or foam (repair). shall meet or exceed:

Seat belt retractor covers or belt covers are 1) Up to October 1982 - manufacturer’s damaged or loose (repair). standard.

Seat air suspension system (if equipped) is 2) October 1982 to September 1987 - leaking air (repair). locking retractor for both portions of

belt. Driver’s seat belt webbing is incorrect color (not orange or lime green for new buses 3) October 1987 to October 1989 -manufactured starting 2009). automatic locking retractor on left side

(locks when belt is pulled out). (Continued on Next Page)

46 2008

A. INSIDE BUS 14. Driver’s Seat and Belt


4) November 1989 to present- three (3) point shoulder harness/lap belt assembly.

5) Type A- manufacturer’s standard all years.

Mounting of retractors or belt guides are insecure.

Seat belt webbing or stitching is frayed or damaged.

Seat belt is routed improperly.

Seat belt does not extend or retract freely.

Seat belt buckle and tongue assembly does not latch or release properly.

47 2008

A. INSIDE BUS 15. Passenger Seats


a. Frames

Inspect passenger seat frames for condition of welds, tubing and hardware, and for incorrect repairs.

Check for presence of non-OEM seat frames.

Check for presence and condition of passenger seat belts on Type A buses built since April 1, 1977. (See page 53 for Type B, C and D buses built starting 2000.)

b. Mounting

Inspect condition of passenger seat mounting.



Out of Service if:

Seat frames or welds are broken or cracked.

Any seat frame is repaired using non-OEM approved hardware or reinforcements.

Any seat frame hardware has been added or modified causing projections or sharp edges.

There are any non-OEM seat frames installed.

Type A buses built since April 1, 1977, must have a functional seat belt at each passenger position. (See page 53 for Type B, C and D buses built starting 2000.)

Seat mounting at floor or seat rail is loose.

Seat mounting fasteners are not OEM or equivalent.

48 2008



c. Backs and Pads

Inspect seat back and foam for specifications and condition.

Requirements:

1) April 1977 to 2007: standard height padded seats with padding that conforms with Federal Motor Vehicle Safety Standards (FMVSS) 222 (i.e., OEM construction specifications).

2) 2007 to present: high-back padded seats (back height approximately 28 inches above seat bottom cushion) with padding that conforms to FMVSS 222, meeting OEM construction specifications.



Out of Service if:

Seat back and padding is of wrong type for specific manufacturer, year, and model bus (see the following requirements):

Original thickness or density of any seat back foam around frame has been significantly reduced due to wear, deterioration, or other factors.

Foam envelope is split, delaminated, or there is no padding between any portion of seat back frame and covering.

49 2008



d. Cuts (and other upholstery damage).

Inspect seat upholstery for condition and specifications.

Seat upholstery is cut, torn, or ripped less than six (6) inches (buses manufactured before November 1989) (repair).

Any portion of seat back or bottom upholstery is missing or repaired improperly, exposing foam.

NOTE: Required fire blocking seat Any passenger seat upholstery is not blue in Seat upholstery is not properly repaired. material must be blue in color starting color (starting September 1995) (repair). September 1995. Seat upholstery is cut, torn, or ripped more

than six (6) inches (pre-November 1989 buses).

Any upholstery has been replaced with non-fire blocking type (starting November 1989).

NOTE: Punctures where no material is Any portion of seat bottom or back upholstery missing and no foam is exposed shall not is cut, torn, or ripped (buses manufactured be cause for removing bus from service. starting November 1989).

Any fire-blocking seat fabric is repaired using procedures that are not approved (starting November 1989).

e. Bottoms

1) Inspect seat bottoms for securement Any seat bottom is not securely attached to and condition. its seat frame.


50 2008

A. INSIDE BUS Passenger Seats


Any seat bottom padding or cushion is significantly deteriorated or damaged.

Any seat bottom has a protruding edge, or its plywood is broken.

2) Inspect flip-up type seat bottom at Any flip-up type seat bottom will not: raise or side emergency door (if equipped) for lower; stay in the raised position; or proper operation. Must have clear automatically retract properly when not access to emergency door with a occupied. minimum aisle width of 12” (inches) between seats. Less than a clear minimum 12” (inch) aisle

width to the side emergency door.

Stanchion or pre-April 1977 modesty panel Any bus manufactured April 1977 to present f. Modesty Panels and Stanchions mounting is loose (repair). does not have a padded crash barrier in front

of any passenger seat that does not have Inspect modesty panels (April 1977 or newer)

(including Courtesy Panels).

another seat in front of it (exception: pre-crash barriers, and stanchions for presence, 1990 Type A Bus) condition, specifications, mounting, and

Stanchions on pre-April 1977 buses are not padding (as required). present or are broken.

Right side modesty panel on post-April 1977 (Continued on Next Page) bus is missing.

Stanchion padding is missing or is damaged so that metal is exposed.

51 2008



Post April 1977-crash barrier is broken, not repaired properly or is mounted improperly.

Crash barrier foam envelope is split or delaminated, or there is no padding between any portion of the barrier frame and covering. Original thickness or density of crash barrier foam around the frame has been significantly reduced due to wear, deterioration, or other factors.

Any portion of the crash barrier upholstery is missing or not repaired properly, exposing foam.

Crash barrier upholstery is cut, torn, or ripped.

Any fire-blocking crash barrier fabric is repaired or replaced using unapproved procedures or non fire-blocking material (buses manufactured starting November 1989).

g. Optional Infant Seating (if equipped) starting September 1995. Seat does not operate or function properly

according to manufacturer’s operational Check the condition and operation of the (Continued on Next Page) procedures. seating system.

52 2008



h. Securement Devices (ifPassenger equipped).

All buses equipped with 2 or 3 point Each two-part belt assembly (if equipped) is passenger securement systems shall be not separately color coded. equipped with FMVSS 210 compliant seat frames and FMVSS 209 compliant belt assemblies in all passenger seating positions where passenger securement systems are installed.

Check type, condition, and operation of Belts knotted, misrouted, retractor covers Belts will not latch or stay latched, are the passenger securement devices. damaged or loose (repair). wrong type, missing, broken, mismatched,

improperly installed, or excessively frayed.

i. Cutter equipped

withWebbing (if No durable webbing cutter is present, or passenger securement devices). webbing cutter is broken or unusable.

Check for presence, proper type, proper Webbing cutter is not securely mounted in mounting, and condition of a durable webbing driver’s compartment within easy reach of a cutter. Secure mounting must provide easy seated and belted in driver, or cutter is removal within easy reach of a seated, difficult to remove. belted-in driver. (Starting October 1993).

Wrong type of webbing cutter.

53 2008

A. INSIDE BUS 16. Emergency Door/Windows/Hatches, and Passenger Check System


a. Operation

Inspect for operation and condition of rear emergency door and side door (buses built after November 1993), door latch, door hold-open feature (buses built after November 1993), door seal, emergency windows, and emergency exits/ventilators (roof hatches).

Rear door opens too far, damaging lights (repair).

Any emergency exit door, window, or hatch latch does not operate smoothly and easily when closing or opening the door, window, or hatch.

Door hold-open feature (if equipped) does not function or secure door in the open position.

Any exit handle or latch mounting hardware is loose (repair).

Mounting of guard for any inside emergency door latch handle is loose (repair).

Any exit handle, handle latch, or mounting hardware is missing.

Inside emergency door latch handle guard is missing (rear door only).

Any emergency exit does not open and close from the inside and outside easily.

Any emergency door or exit is equipped with any type of a hasp, lock, or any other locking device, except for an OEM interlock system.

Bus will start with any emergency door locked (OEM interlock system).

Weatherstrip does not seal.


54 2008

A. INSIDE BUS 16. Emergency Door/Windows/Hatches, and Passenger Check System


Emergency window latch does not latch window securely or window does not open easily.

Roof hatch seal is damaged or dislodged Roof hatch does not open easily to full (repair) “emergency open” position.

Roof hatch power ventilator (if equipped) Roof hatch does not open to ventilation does not work properly (note). position.

b. Buzzers

Check operation of warning buzzers for Buzzer gives false alarms (repair). Buzzer warning system for emergency door, emergency door and emergency exit or any exit window, does not function, or is windows. not audible in the driver’s compartment.

Buzzer operation is intermittent.

c. Labeling and Pad

1) Inspect for label and operating Hold-open device labeling (if applicable) is All emergency exits are not clearly labeled instructions for emergency door, missing or not readable (repair). “Emergency Door” or “Emergency Exit” on emergency windows, and emergency the inside and outside of the bus. exit/ventilators (roof hatches), and hold-open device labeling (if There are no operating instructions on the applicable). inside of the emergency door.


55 2008

A. INSIDE BUS 16. Emergency Door/Windows/Hatches, and Post-Trip Passenger Check System


Any emergency hatch does not have clearly Any roof hatch does not have clearly labeled labeled operating instructions on the outside operating instructions on the inside of the of the hatch (repair). hatch.

Any emergency exit window does not have clearly labeled operating instructions on the inside of the window.

2) Inspect emergency door header pad. Door pad is ripped or loose (repair). Door pad is missing or has a protruding edge.

d. Post-Trip Passenger Check System (if applicable)

Check for proper operation of post-trip Post-trip passenger check system (if passenger check system (required on required) does not operate according to buses manufactured starting 2005). manufacturer’s specifications, or is not

working (repair).

56 2008

A. INSIDE BUS 17. Windshield, Side & Rear Windows


a. Glass Cracks

Inspect windshield and all windows for cracks and other damage.



Out of Service if:

There are any cracks in the windshield in the driver’s direct field of vision or any pock marks that obstruct the driver’s vision.

There is any crack in the windshield or any window greater than two (2) inches in length.

There is any glass missing.

There is any laminated windshield or laminated window glass broken or splintered that might cause injury when touched.

There is any window to the side of the driver or behind the driver’s location that is not laminated or tempered safety glass or Lexan or equivalent.

There is any crack in non-laminated safety glass.

57 2008



b. Fogging

Check windshield and windows for fogging, Glass fogged less than two (2) inches in from The windshield or any window is fogged more reduced visibility, or improper level of tinting. any outer edge (note). than two (2) inches in from any outer edge.

Any windshield or window fogging or clouding results in reduced visibility of a mirror.

There is any reduced visibility through the windshield or any window(s) (other than fogging that is less than two (2) inches in from any outer edge).

There is tinting on the windshield, or windows to either side of the driver, that is not 70% light transmitting or clearer.

There are any tinted windows behind the driver’s compartment that are not 28% light transmitting or clearer.


58 2008



c. Latches and Window Operation

Check latches and windows for condition and Any window latch is hard to operate, or any Any window latch is broken. operation. window does not move up and down freely

(repair).

Any window will not stay closed (repair). Any window will not move (full travel) up and down.

There is loose, damaged, or protruding window hardware in the passenger compartment.

d. Visor

Check drivers sun visor for condition and Driver’s sun visor is too tight or cannot be operation. adjusted.

Driver’s sun visor is cracked, damaged, clouded, dirty, or will not stay in position or has unauthorized stickers.

Sun visor is missing.

59 2008

A. INSIDE BUS 18. Wheelchair Lift Door & Securement System


Wheelchair Lift, Door, and Securement System

1) Operate lift through complete cycle and inspect for proper operation, condition, safety features, manual backup system, fluid seepage or leaks, mounting, barrier operation, warning light, buzzer operation, and overall mechanical condition. (See page 136 for definitions of fluid “seepage” and fluid “leaks.”)

Dome light at inside lift area is inoperative (repair). Lift door or latch does not operate smoothly (repair).

White light at exterior lift area (if originally equipped) is inoperative (repair).

Lift control cable or wiring is damaged or routed improperly (repair).

Lift door warning buzzer or light does not operate.

Lift door latches, weather stripping, or securement system is damaged or loose.

Door switch (to prevent lift operation when the lift door is closed) or other safety override features do not function.

Lift will not stay in the fully retracted position (falls against door).

Lift safety chain or belt (if originally equipped) is damaged or missing, or lift safety interlock system is not operating according to manufacturer’s specifications.

Lift platform end barrier or handrail does not raise and lower reliably to the proper position. Barrier does not lock in position, or is damaged.

(Continued on Next Page) Lift does not fold, unfold, raise, and lower properly, or jerks and/or binds.

60 2008



There is excessive side play (more than two (2) inches) in the lift mechanism when the platform is partially or fully extended.

NOTE: See page 136 for definitions of fluid “seepage” and “leaks.”

There is fluid seepage at the lift (note). Lift leaks fluid onto or below floor.

Lift is not mounted securely to the vehicle.

The lift jacks the vehicle.

Lift on 1989 or later buses (large end barrier-type lift) is not equipped with frame padding.

Any part of the lift mechanism or hardware is damaged, missing, or not secure, including cams, clips, pins, rollers, and platform fasteners.

Manual backup system does not function properly.


61 2008



2) Inspect wheelchair and occupant securement (tie-down) system for proper operation, condition, mounting, proper type, and location.

Track is filling with dirt but occupant securement straps and wheel chair tie-down straps can still be attached to or detached from track (repair).

Wheelchair tie-down track or fasteners are loose, broken, or sections of track are not continuous within each wheelchair position (pre-1989 only).

Wheelchair or occupant securement straps are broken, frayed, cannot be easily attached to or detached from track, or will not operate.

Securement system for buses built between October 1983 and November 1989 is not a side facing track and belt system meeting Florida Specifications.

Securement system (for buses built after November 1989) is not a forward facing wheelchair and occupant securement system meeting Florida specifications.

3) Check for presence, proper type, proper mounting, and condition of a durable webbing cutter. Secure mounting must provide easy removal within easy reach of a seated, belted-in driver. (Starting October 1993).

Wheelchair or occupant securement track is mounted using self-threading hardware (lag bolts, sheet metal screws, etc.) or track is filled with dirt.

No durable webbing cutter is present (if required).

Webbing cutter is not securely mounted in driver’s compartment within easy reach of a seated, belted-in driver.

62 2008

A. INSIDE BUS 19. 2-Way Radio Operation (If Equipped)


2-Way Radio Operation

Inspect radio and antenna for condition, mounting and location, and routing of wiring, and perform function check.

Radio will not transmit or receive (repair).

Mounting is loose (repair).

Driver has to move out of the normal driving position to operate radio.

Wiring or connectors are not insulated, installed improperly, misrouted, or there is the possibility of an electrical short circuit due to unsecured or damaged wiring.

63 2008

A. INSIDE BUS 20. Interior Wiring, Cab Hoses, & Fire Wall Seals


a. Interior Wiring

Inspect visible wiring for mounting, condition, Wiring or connectors are unsecured, Any wire or connector is cut or severely chafing, abrasion, corrosion, loose corroded, or improperly routed (repair). chafed, is missing insulation, or is routed connectors, or improper repairs. against a sharp edge, or there is interference

with driver's controls. b. Cab Hoses

Inspect all hoses for leaks, condition, routing, Hose is weathered, cracked, abraded, or There is any unshielded heater hose in the abrasion, and presence of heater hose routed improperly (note). Any hose in driver’s driver’s compartment (starting November shielding (shielding required starting compartment is seeping lubricant or coolant 1980). Any hose in driver’s compartment is November 1980). (See page 136 for (repair). leaking lubricant or coolant. definitions of seepage and fluid leaks.)

c. Firewall Seals

Inspect firewall for any holes, cracks, Sound deadening/insulation is missing, There is any open hole or unsealed area in unsealed openings, and deteriorated or unsecured, or deteriorated (repair). the firewall. missing sound deadening/insulation material.

64 2008

A. INSIDE BUS 21. General Condition, Bus Interior


a. Floor

Inspect floor covering, plywood sub-floor (if Floor covering material is loose, deteriorated, There are any unsealed holes or cracks installed), aisle and cove molding strips, and or cracked (repair). through floor to underside of bus. ribbed rubber in aisle for condition, adhesion, loose or missing fasteners, and/or fastener Plywood is rotten or soft (repair). Aisle is not equipped with 12 inch wide ribbed holes or cracks. rubber.

Cove molding is loose or fasteners are loose Any aisle molding strip is not securely or missing (repair). fastened to floor or any aisle or cove molding

presents a sharp edge or protrusion.

There is any damage to floor covering material that could create a tripping hazard.

Step warning decals are missing or unreadable (flat floor equipped buses only). b. Stepwell

Check specification and condition of stepwell Step tread is not secure or sealed at inside Stepwell tread and leading edge at aisle are and tread. edge where it meets next step (repair). not flush and securely adhered, causing a

tripping hazard.

Stepwell tread ribs/nubs, on top surface at leading edge, are worn smooth more than four (4) inches in width.

Stepwell support structure is broken, or stepwell is rusted through.


65 2008


Inspection Procedures: Repair (or note) if: Out of Service if: Any Type C or D bus manufactured starting December 1990 is not equipped with a three-step riser with full-width steps.

The stepwell area has been damaged or weakened to the extent that a hazard exists.

c. Grab Rail(s)

Check for presence and secure mounting of Entrance grab rail(s) is missing or not entrance grab rail(s). securely mounted.

Lift equipped bus does not have a front and rear grab rail at the entrance stepwell.

Check handrail(s) for required modification(s) Handrail(s) has not been modified as required Handrail(s) fails NHTSA string and nut test. (if equipped). If required modification is not (repair). present, perform a NHTSA string and nut test.

d. Paneling

Check all interior sidewall, rear, ceiling, and There is graffiti or unauthorized stickers on Sharp edges, rust-through, loose fasteners, driver’s area paneling for secure fastening, interior panels (repair). or projections from paneling exist that could projections or sharp edges, and condition. cause injury to passengers or driver.

There are loose or missing fasteners on any maintenance access panel (repair). There are any non-flush mounted speakers

(except trim rings) or any other unauthorized Interior paneling is mildewed, or paint (where items affixed to the interior paneling of the required) is missing or damaged (note). bus in the passenger area.


66 2008



e. Broom Mounting

Check securement and location of broom. Broom is not securely mounted in the driver’s compartment.

f. Loose Objects Secured

Check to see that all objects within the bus Loose objects such as trashcans, clothing, are secured. cleaning supplies, or other loose items are

present that are not located in a secured compartment or container.

Check for the presence of aerosol containers Any aerosol can(s) or other container(s), with and non-aerosol liquid containers. flammable or volatile contents are present.

Any aerosol container or liquid container is present with contents not clearly labeled.

g. Dog House/Engine Cover

Inspect dog house/engine cover seals, sound Soundproofing is not present, or is loose or Seals or weather stripping are leaking and proofing, weather stripping, prop-rod and deteriorated (repair). allowing air/fumes into driver’s compartment. latch operation.

Prop-rod does not safely support the dog house/engine cover.

Latch(s) are hard to operate or do not secure the dog house/engine cover properly.

67 2008

B. OUTSIDE BUS 1. Headlights, Turn Signals, Hazard, Side Marker, Brake Lights, Tail Lights, Backup

Lights, Backup Alarm (if equipped), Parking Lights, and LED Type Lights


a. Headlights

Check both headlights for brightness, Left and right sealed beams are of different Either sealed beam does not light on low and operation, condition of sealed beams, and type (halogen vs. conventional) (repair). high. visible misaiming. Check high beam indicator operation and headlight switch. Any sealed beam lens is fogged or cracked,

or light is dim. Check Daytime Running Lamps (DRL) (if DRL system does not work according to equipped) for proper operation. specifications (repair). High beam indicator doesn’t light.

Dimmer switch sticks, is hard to operate, or doesn’t function.

Headlight switch is damaged or not securely mounted, or knob is missing.

Lights go out after being on a short time, or operation is intermittent.

Upon visible inspection, there is any obvious misaiming of headlights.

b. LED Type Lights

While checking lights, check all light emitting Any single LED element does not work (if 25 % or more of the LED elements in any diode (LED) elements in all LED type lights. equipped). LED type light are not working.


68 2008

B. OUTSIDE BUS 1. Headlights, Turn Signals, Hazard, Side Marker, Brake Lights, Tail Lights,

Backup Lights, Backup Alarm (if equipped), and Parking Lights


c. Turn Signals

Check turn signals (including bulbs and lenses) for operation, condition, and specifications (see Chart 6 and 7 on pages 85 and 86).

Any turn signal lens is cracked (repair). Any turn signal does not flash or is dim.

Turn signals do not flash 60 to 120 times per minute.

Bus is manufactured since December 1990 (any Type C bus over 29 capacity or any Type D bus) and is not equipped with side-mounted turn signals.

Turn signal indicator does not properly indicate right and left (position of turn signal switch).

Turn signal switch does not function properly or will not maintain selected position.

Turn signal switch does not cancel or return to neutral position.

Any turn signal lens on buses built since September 1985 is not amber.

Any turn signal lens is damaged, and white light is visible.

(Continued on Next Page) Any turn signal lens has darkened, faded, or is dirty, significantly affecting visibility or color of the light.

2008 69




d. Hazard

Check four-way hazard lights for operation Any lens is cracked or dirty (repair). Any four-way hazard light fails to function. and condition.

Hazard lights do not flash 60 to 120 times per minute.

Switch does not function or will not maintain set position with steering wheel in the straight-ahead position.

e. Side Marker

Check side marker lights (if installed) for Any side marker light fails to function or is operation and condition. cracked or damaged (repair).

f. Brake Lights

Check brake lights and lens(es) for One brake light on either or both sides fails Both brake lights on one side fail to function operation, condition, and specifications (see to function (four (4) brake light systems only) (four (4) brake light system). Chart 7, page 86). (repair).

For buses built with one brake light per side (buses built prior to November 1980), either brake light fails to function.

(Continued on Next Page) After brake pedal is released, brake lights stay on.

70 2008

B. OUTSIDE BUS 1. Headlights, Turn Signals, Hazard, Side Marker, Brake Lights Tail Lights,



Any 19 capacity or larger bus built since November 1980 is not equipped with two (2) seven (7) inch and two (2) four (4) inch brake lights.

Any brake light lens is cracked (repair). Any brake light lens is loose, incorrectly installed, or damaged, causing white light to be visible.

Any brake light lens is not red or is not proper type meeting SAE specification.

g. Tail Lights

Any brake light lens has darkened, faded, or is dirty, significantly affecting the visibility or color of the light.

Check tail light(s) and lens(es) for operation, condition, and specifications (see Chart 7, page 86).

One (1) tail light on either or both sides fails to function (four (4) tail light system only) (repair).

Both tail lights on one (1) side fail to function when headlight switch is in either the park or headlight positions (four (4) tail light system).

One tail light on either side fails to function (two (2) tail light system).

Any 19 capacity or larger bus built since November 1980 is not equipped with two (2) seven (7) inch and two (2) smaller tail lights.

Any tail light lens is cracked (repair).


Any tail light lens is damaged and white light is visible.

71 2008



Inspection Procedures: Repair (or note) if: Out of Service if: Any tail light lens is not red or is not proper type meeting SAE specifications.

Any tail light lens has darkened, faded, or is dirty, significantly affecting the visibility or

h. Backup Lights color of the light.

Check backup lights for proper operation and One (1) of two (2) backup lights (if equipped) Any bus is not equipped with at least one (1) condition (see Chart 7, page 86). doesn’t function (repair). functional white backup light.

Any backup lens is cracked (repair). Backup light(s) stays on all the time or stays on in any gear position other than reverse.

i. Backup Alarm

Check for presence of backup alarm (buses Dash sticker is not mounted on dash in plain Backup alarm does not sound. manufactured starting November 1990) and view of the driver (repair). dash sticker (starting November 1993). Check proper operation of alarm (or variable Dash sticker is not present (starting volume alarm if equipped) by placing November 1993) (repair). transmission in reverse (engine running) and listening for alarm sound. Variable volume backup alarm (if equipped)

is not variable (repair).


72 2008




j. Parking Lights

Check parking lights for proper operation and condition (see Chart 6 and 7, pages 85 and 86).

One (1) front parking light does not function on either side (four (4) parking light system) (repair).

Any parking light lens is cracked or damaged (repair).

Both front parking lights on either side (four (4) parking light system, if equipped) do not function in parking or headlight positions.

One parking light fails to function (two (2) parking light system, if equipped).

73 2008

B. OUTSIDE BUS 2. Clearance & ID Lights, Reflectors and Strobe

Light (if equipped)


a. Clearance and ID lights

Check light(s) and lens(es) for operation, Any single clearance light on the front of the All clearance lights on either side of the bus condition, and location. Also check license bus fails to function (repair). are inoperative. plate light (See Chart 6 and 7 on pages 85 and 86). One or two ID lights (but not all ID lights) on All clearance lights on the front of the bus are

the front or rear of the bus fail to function inoperative. (repair).

Any single corner-mounted clearance light is inoperative.

All ID lights on either the front or the rear of the bus are inoperative.

Any clearance light switch (on buses Clearance lights (on buses manufactured manufacturered prior to September 1985) is starting September 1985) are not activated hard to operate or sticks, or knob is missing and deactivated by the headlight switch. (repair).

Any clearance or ID light lens is damaged or Any rear clearance or ID light lens is not red, white light is visible (repair). or any intermediate or front clearance or ID

lens is not amber.

Any clearance or ID light lens has darkened, faded, or is dirty, significantly affecting the visibility or color of the light.


74 2008


Light (if equipped)


License plate light is inoperative (repair). Any bus over 30’ in length is not equipped with intermediate amber clearance lights on both sides.

b. Reflectors

Check reflectors for condition and location (see Chart 6 and 7 on pages 85 and 86).

Reflectors are required as follows: 1) Buses over 30’ in length: two (2)

red on rear, one (1) red on each side at rear, one (1) intermediate amber on each side, and one (1) amber at front and one (1) amber front of cowl on each side.

2) Buses under 30’ in length: same, except intermediate amber are not required.

Any reflector is damaged or cracked (repair). Any required reflectors are missing.

Any required red reflector is faded, significantly affecting its original color.


75 2008


Light (if equipped)


c. Strobe Light

Check roof mounted white flashing strobe light for operation, location, and condition.


Any bus manufactured starting December 1990 is not equipped with a roof-mounted white flashing strobe light mounted in the center of the roof approximately 48 inches from the rear of the bus.

The strobe light on any bus built prior to December 1990 is not mounted in the center of the rear part of the roof.

Strobe light does not function.

76 2008

B. OUTSIDE BUS 3. Pupil Warning Lights


Pupil Warning Lights

Check pupil warning lights for operation and Either pupil warning light pilot light fails to Any amber or red light does not function or is condition (see Chart 6 and 7 on pages 85 function (repair). dim. and 86).

Amber/red lights (both front and rear) do not NOTE: See Chart 5, page 78, for function checks. alternately flash ( side to side).

Any pupil warning light is not red (outer) or NOTE: Pupil warning light hoods front and rear are not required starting amber (inner) or is not proper type meeting

SAEJ760 (December 1974), SAE specifications (June 1976), and SAE specifications May 1982 (Revised May 1982).

September 1993.

Any pupil warning light lens is damaged, and white light is visible.

Any pupil warning light lens is obstructed, has become darkened, faded, is misaimed, or is dirty, affecting the color of the light or reducing the visibility to less than 500 feet in bright sunlight.

Pupil warning lights do not function according to all conditions in Chart 5, page 78.

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CHART 5 EIGHT-LIGHT WARNING SYSTEM

NOTE: System may not be designed in such a way that the operator is required to actuate controls in a particular sequence to achieve the desired combination of conditions.

EXAMPLE: If the driver places the three-position switch in the amber position with the master switch “ON,” it must not be required that the three-position switch be moved to “RED” or that the service door be opened in order to deactivate the “AMBERS.” In this example, the driver must be able to deactivate “AMBERS” by going directly from the AMBER to the OFF position.

WITH MASTER SWITCH, CONTROL SWITCH, and SERVICE DOOR CONDITION OF STOP ARM(S), STOP ARM LIGHTS, AMBER IN THE FOLLOWING POSITIONS: WARNING LIGHTS AND RED WARNING LIGHTS MUST BE:

MASTER CONTROL AMBER SWITCH SWITCH SERVICE STOP ARMS, WARNING RED WARNING *AUDIBLE

POSITION POSITION DOOR STOP ARM and and ALARM (ON or OFF) (three-positions: OFF, POSITION LIGHTS PILOT LIGHTS PILOT LIGHTS

AMBER, or RED)

1) ON OFF CLOSED RETRACTED, OFF OFF OFF OFF

2) ON OFF OPEN RETRACTED, OFF** OFF ON ON

3) ON AMBER CLOSED RETRACTED, OFF ON OFF OFF

4) ON AMBER OPEN RETRACTED, OFF** OFF ON ON

5) ON RED CLOSED EXTENDED, ON OFF ON OFF

6) ON RED OPEN EXTENDED, ON OFF ON OFF

7) OFF ANY POSITION ANY POSITION RETRACTED, OFF OFF OFF OFF

* NOTE: Effective September 1, 1992. **NOTE: The stop arm lights may flash when stop arm is retracted on buses built prior to November 1983.

78 2008

B. OUTSIDE BUS Stop Arm(s)


a. Stop Arm(s)

Check stop arm(s) for specifications, Wiring-ground strap is loose or not properly Wires or ground strap(s) is broken. operation (fully extends 90° (degrees) +/- 5° routed and secured (repair). (degrees), and condition (see Chart 7, page Any stop arm light does not flash or lights do 86). not flash 60 to 120 times per minute.

Hinge or bushing(s) is dry of lubrication Stop arm does not extend or retract or is (repair). slow to extend or retract.

Stop arm assembly or blade mounting is Any stop arm has an air or vacuum leak. loose (repair).

Any stop arm (paint or decal) is significantly +/- 5° (degrees)(repair). Stop arm extends more than 90° (degrees)

faded or discolored.

Stop arm does not operate according to all Stop arm extends less than 90° (degrees) +/-the conditions in Chart 5, page 78. 5° (degrees) (repair).

Stop arm(s) not of proper type and specifications:

1) Webfoot, January 1965 to September 1985.

2) Octagonal, September 1, 1985. 3) Alternately flashing red lights, all

years. 4) Reflective white border and lettering,

March 1, 1977. (Continued on Next Page)

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B. OUTSIDE BUS Stop Arm(s)


5) High intensity reflectivity, starting December 1990.

6) stop arms required on allDual modified Type B and Type C 47 passenger capacity and up and all Type D starting December 1990.

Check that rear stop arm decal has been A stop arm decal has been installed on the deleted on buses built after September 1, forward side of the rear stop arm for buses 1993. built after September 1, 1993.

b. Student Crossing Arm (if equipped)

Check front bumper mounted student Not equipped with student crossing arm, crossing arm for specifications, operation

Crossing arm extends more than 90° starting December 1992.

(fully extends 90° (degrees) +/- 5° (degrees), condition, and mounting.

(degrees) +/- 5° (degrees) (repair).

Crossing arm does not extend or retract or is Crossing arm extends less than 90° slow to extend or retract. (degrees) +/- 5° (degrees) (repair).

NOTE: Crossing and stop arm extension, labeling, and other Crossing arm is leaking air. Crossing arm assembly or blade mounting is requirements are found in loose (repair). Federal Motor Vehicle Safety Standard (FMVSS) 131. Hinges or bushings are dry of lubrication

(repair).

80 2008

B. OUTSIDE BUS 5. General Condition, Bus Exterior


a. Mirrors

Check all exterior mirror mounts brackets for tightness and condition.

and Mirror mounts or bracket(s) are bent, broken, or insecure.

Any exterior review mirror is broken, cracked or loose in the frame.

b. Bumpers

Check bumpers for mounting, condition, color, and body seal (rear bumper).

Bumper is not black (repair). Bumper is significantly bent or has protruding metal.

Bumper is equipped with any unauthorized stickers or decals (repair).

Bumper mounting system has cracked, broken, or there are bent brackets, braces, or welds, or missing or loose fasteners.

Rear bumper body seal (if equipped) is damaged or missing (note).

Diagonal reflective striping (if equipped) is missing, significantly damaged, or is not reflective.

Front bumper on buses built starting October 1982 permanently deforms or is not of sufficient strength to allow lifting front of bus without permanent deformation.


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c. Body Damage

Check body exterior for damage, scratches, Body has small dents, scratches, etc. Any body part is damaged or dislocated, dents, etc. (repair). creating a protrusion or sharp edge.

Body has small rust spots or water leaks Body panels, rivets, or other components are (repair). damaged or corroded to the point where joint

strength or body structural integrity is compromised. d. Paint

Check paint on body trim and wheels for Paint is faded, discolored, or damaged Paint is not National School Bus Yellow required coloration and condition. (repair). (except white roof). Trim, rub rails, warning

light hoods, or background are not black. Stud-piloted disk wheels or spoke hub- mounted wheels are not black, or hub-piloted wheels are not National School Bus Yellow.

e. Reflective Markings (if equipped)

Check reflective markings for coloration, Reflective markings, other than those around Any required reflective markings are missing, reflectability, and condition. Reflective any emergency exit door or roof hatch, as or significantly faded or discolored, around markings required starting September 1995. required by F.M.V.S.S. 217, are faded, any emergency exit, door, or roof hatch.

discolored, damaged, or peeling (repair). Check for presence of reflective markings around any emergency exit, door, window, or roof hatch as required by F.M.V.S.S. 217 (buses purchased after November 1993).


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f. Lettering

Check all lettering for required type, size, Bus is not equipped with following lettering Bus is not equipped with following lettering: location, and color (see Chart 6 and 7 on (repair):pages 85 and 86).

1) Eight inch (8”) “SCHOOL BUS” front Handicapped symbol (front and rear; Note: See Florida school bus specifications and rear. 1) buses built starting September 1984 for additional lettering requirements. “Name District Schools” on left and if wheelchair lift equipped).

2) right sides of body: four inch (4”) 2) Minimum two inch (2”) lettering starting November 1978 and six inch “Emergency Door” at top or above (6”) starting 1993. door.

3) Local bus number: rear and both 3) Emergency window(s) or hatch(es) sides. (Front and rear and both sides labeled “Emergency Exit” from inside starting 1998). and outside (buses built starting

December 1990). Any required lettering is not black (except 4) Fuel type lettering is not present handicapped symbol, local bus number if (buses built starting September located on bumper, and/or emergency door 1985). hold open device labeling). (repair).

There is not at least one local bus number and District Name present on the exterior. Any required lettering is not clearly readable

(repair). Any handicapped symbol (if required) is not reflective, white on blue background, andExterior emergency hatch operating minimum six inches by six inches (6”x6”). instructions are not clearly readable (repair).


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g. Emergency Door Operation

Check emergency door for operation from exterior of bus.

h. Engine Hood

Check engine hood for operation, condition, and safety latch.

i. Cleanliness

Check exterior of bus for cleanliness.

Hood is misaligned (repair).

Hood hinges are not lubricated or are damaged (repair).

Exterior of bus is dirty (note).

Emergency door is hard to open fully from outside of bus.

Emergency door latch mechanism requires more than 40 pounds to release.

Emergency door handle is mounted to allow “hitching” onto the bus.

Hood cannot be opened as designed.

Safety latch does not secure hood, is not lubricated, or is damaged.

Hood prop rod(s) or hold-open feature does not function properly.

Bus is dirty to the point visibility through any window or light lens is significantly reduced.

84 2008

Chart 6 MINIMUM LETTERING AND LIGHTING REQUIREMENTS

A. Clearance Lights

Stop Arm(s)

C. Front Turn Signals and Parking Lamps

F. Pupil Warning Lights--Dual (side by side, amber and red) BB.

G. Reflectors, one at rear body side panel, one near front of body, and one intermediate (only on buses 30 feet or longer) on both sides

I. Emergency Exit

J. Double Faced Flashing Red Lights

K. “School Bus” Lettering (front and rear) (see specifications)

L. (Name of District) District Schools (both sides)

M. Local Bus Number (both sides and front and back)

N. Universal Handicapped Symbol (lift buses)

O. Identification Lamps

S. Battery Box

U. Pupil Crossing Arm

Y. Rear-View Mirror System (see specifications)

Z. Cross / Side View Mirror System (see specifications)

85 2008

CHART 7 MINIMUM LETTERING AND LIGHTING REQUIREMENTS

A. Clearance Lights I. Emergency Exit Lettering P. Backup Lights

B. Seven-Inch Brake/Tail/Parking Lights K. “School Bus” Lettering (front and rear) R. Fuel Door (see specifications)

C. Seven-Inch Turn Signals (amber) T. Wheelchair Lift Landing Light L. (Name of District) District Schools

E. Four-Inch Brake/Tail/Parking Lights Y. Rear View Mirror System M. Local Bus Number (all sides)

F. Pupil Warning Lights--Dual (side-by- Z. Cross / Side View Mirror System side amber and red) N. Universal Handicapped Symbol (lift

buses) AA. Roof-Mounted White Strobe Light G. Reflectors

O. Identification Lamps CC. Rear Door Lettering (see specifications) H. License Plate Lamp (one minimum)

86 2008

C. ENGINE COMPARTMENT Steering


a. Play

Check for play in the steering system, at the Free play (lash) exceeds amounts specified steering wheel, using the following in Chart 8, page 88. procedures:

Steering wheel OEM covering is loose, OEM covering is loose, deteriorated, 1) Visual check - from inside bus with deteriorated, or cracked (repair). cracked, or missing exposing metal steering

engine running, rotate steering wheel wheel reinforcement. lightly from side to side until the turning motion can be observed at Steering wheel is loose on column. tires, then measure free play (lash) at steering wheel outer diameter. This Steering wheel is non-OEM design. procedure must be performed with the vehicle on the ground.

2) To check power assist operation, run Power assist is inadequate, or there is engine at fast idle, turn steering binding, jamming, or belt slippage. wheel a full right and left turn, and feel for binding, jamming, or belt slippage.

b. Column

Check steering column inside bus for up and Side-to-side play in steering column exceeds down play (parallel to shaft), side-to-side 1/4 inch or up and down play exceeds 1 inch. play (perpendicular to shaft), and for proper mounting. Column assembly mounting (including floor

mounting plate) or fasteners are loose. (Continued on Page 89)

87 2008

CHART 8

STEERING WHEEL PLAY (LASH) MEASUREMENTS

Figure 1 Figure 2

Steering Wheel Size 15 inches - 1 3/4” (4.4 cm)

Wheel Size: 16 inches or less - 1/4” (6.5 mm)

16 inches - 2” (5.1 cm) 17 to 18 inches - 3/8” (9.5 mm) 18 inches - 2 1/4” (5.7 cm) Over 18 inches - 1/2” (13 mm) 20 inches - 2 1/2” (6.4 cm) 22 inches - 2 3/4” (7.0 cm)

88 2008

C.

1.

ENGINE COMPARTMENT Steering


c. Steering Gear Box and other external components must be checked using the following procedure:

1) Vehicle should be on ground (not suspended).

2) With engine running, have assistant move steering wheel back and forth repeatedly to load steering components.

3) Visually observe the following external steering and related suspension and frame components for looseness while assistant works steering (also see specific procedures under each component):


Tilt/telescopic assembly (if equipped) will not stay locked in position.

Steering column U-joint inside the bus (if equipped) is loose, damaged, or noisy after lubrication.

Firewall rubber boot at floor (if equipped) is torn, or ripped, or missing.

Column U-joint (if equipped; see Figure 3, page 91) is loose, damaged, or noisy after lubrication.

Flexible coupling, if equipped (rag joint, Figure 4, page 91) has loose or missing fasteners, damaged flexible disc, or elongated holes.

Any column U-bolt, pinch bolt, other column fasteners, or input shaft coupling is loose, damaged, or missing.

89 2008

C.

1.

d) e) f)

h)

ENGINE COMPARTMENT Steering


a) Column shaft and hardware Pot joint, if equipped (shell coupling; See b) Column U-joints or flexible Figure 5, page 91), is loose.

coupling (as equipped) c) Coupling at gear box Pot joint (shell coupling) rubber is damaged Pot joint (shell coupling) rubber is missing.

Gear box or torn (repair). Pitman arm Steering gear box is loose on frame or Drag link fasteners, or lock tabs are loose or missing.

g) Steering knuckle or arms Tie rod ends Frame braces or crossmembers are cracked.

i) Idler arm (as equipped) j) Vehicle frame cross-members Rivets or other fasteners at frame braces or

and frame braces (including crossmembers are loose or missing. associate rivets and fasteners for looseness and condition) Any axle or suspension component is loose

beyond specifications prescribed elsewhere 4) Have assistant carefully operate in this manual.

steering to full left and right turn and check for power assist pop-off and steering stops.

5) As follow-up to the above steering check, also perform a visual and hands-on check of each of the listed components. See the following details on pages 93 through 95.

(Continued on Page 93)

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c. Steering Gear Box Mounting

Check mounting, condition, and tightness of Steering gear box is loose. steering gear box, and check frame, frame braces, and associated rivets or fasteners for There is any binding in steering gear box. looseness and condition.

Frame, frame braces, and associated rivets or fasteners are loose, damaged, cracked, or missing.

d. Pitman Arm

Check the Pitman arm for looseness or Pitman arm grease fitting (if originally Any play is observed between Pitman arm misalignment at sector shaft splines and equipped) is loose or missing (repair). and sector shaft. looseness at all joints. Check looseness of pinch bolt and fasteners and condition of Pinch bolt at sector shaft is loose or missing. Pitman arm.

Pitman arm to sector shaft-timing marks is misaligned.

Pitman arm ball joint (if equipped) has more than 1/16 inch play (axial, i.e., in and out play between the ball stud and socket). (See Figure 6, page 96.)

Pitman arm ball joint (if equipped) has loose or missing nut, or cotter pin is missing.

Pitman arm is cracked or damaged. (Continued on Next Page)

93 2008



e. Drag Link

Check the drag link ends, shaft, and Any grease fitting (as equipped) is loose, Drag link ball stud is loose in Pitman arm or fasteners for looseness and condition (on missing, or will not take grease (repair). upper steering arm. vehicles with I-beam suspension).

Drag link end boot is damaged or missing Any nut is loose or missing, or cotter pin is (repair). missing.

Drag link needs lubrication (repair). Drag link shaft is damaged or bent.

Drag link dust boot (as originally equipped) is Drag link end (nonadjustable type) has more cut, damaged, or missing (repair). than 1/16-inch axial play (See Figure 6, page

96).

Horizontal socket type (adjustable) drag link end has more than 1/16-inch axial or lateral play.

f. Steering Arm

1) Check upper steering arm (Ackerman Any steering arm is bent, cracked, or arm) and left and right side lower damaged. steering arms for securement and condition. Any steering arm attachment point is loose,

or any fasteners or cotter pins are missing.

2) Check condition and securement of Either steering stop or lock is loose, steering stops and lock nuts. damaged, or missing.(Continued on Next Page)

94 2008



g. Tie Rod and Ends

Check tie rod ends, tie rod, dust boots, and Tie rod end dust boot is cut, damaged, or Tie rod clamps, fasteners, or cotter pin is clamps or fasteners (as equipped) for missing (repair). stripped, missing, or loose. looseness, damage, and condition.

Tie rod end needs lubrication (repair). Any clamp (as equipped) is improperly positioned.

Any tie rod end grease fitting is loose, missing, or will not take grease (repair). Any tie rod or end is cracked or damaged.

Any tie rod end has more than 1/16 inch axial play (See Figure 6, page 96).

Tie rod end ball stud is loose in steering arm or idler arm.h. Idler Arm

Check idler arm assembly (as equipped) for Idler arm needs lubrication (repair). Any idler arm fasteners are loose or missing. looseness, damage, and condition.

Idler arm grease fitting is loose, missing, or Idler arm is cracked or damaged, or cotter will not take grease (repair). pin is missing.

Idler arm up and down play is greater than 1/4 inch total (1/8 inch either direction). (See Figure 7, page 96.)

95 2008

FIGURE 6 - Checking the Rod and Drag FIGURE 7 - Checking Idler Movement, Typical Link End Movement

A Movement in the axial direction must be less than 1/16 inch.

B Tie rod/drag link free to rotate within steering arm socket.

1 Tie rod/drag link end Steering arm

2

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97 2008

C. ENGINE COMPARTMENT Batteries


a. Hold-down

Check for tightness, condition, and type of battery hold-down.

b. Battery Terminals

Check terminals for cleanliness, tightness, and condition.

c. Battery Cables

Check cable assemblies for routing, securement, condition, and size.


Hold-down assembly or tray is loose, corroded, or damaged, causing insecure mounting of battery.

Hold-down is a flexible strap or other non-rigid design.

Any terminal is loose, damaged, corroded, or has missing hardware.

Any positive terminal has missing insulation.

Cable or insulation is cracked or damaged, or cable is corroded.

Cable is misrouted or unsecured, or grommet is missing to allow it to abrade on any metal or sharp edge.

Cable is routed against the exhaust or any other extremely hot surface.

Cable is smaller than original equipment size.

98 2008



Cable appears to be too small in diameter or of excessive length (see Chart 9, page 100).

Flat braided engine ground cable is frayed or corroded, or ends are not secure.

d. Cleanliness

Check cleanliness of battery or batteries. Battery top or sides are corroded, greasy, Battery is cracked or damaged. dirty or wet with electrolyte (repair).

e. Tray

Check battery tray for operation, condition, Battery slide tray is corroded, dirty, or hard to Battery slide tray securement device or tray and securement. slide in and out (repair). stop is missing or nonfunctional.

Battery tray does not slide in and out.

Battery slide tray or box is damaged or deteriorated, reducing security of battery or batteries.

Battery box door does not open or will not stay latched.

f. Electrolyte Level

Check electrolyte in battery or batteries for Electrolyte is low (repair). Electrolyte is too low, exposing plates. proper level (if applicable).


99 2008

CHART 9

CHARGING SYSTEMS CABLE SIZE CHART

SYSTEM VOLTAGE

RATED OUTPUT

IN AMPERES

RECOMMENDED MINIMUM CHARGING CABLE GAUGE SIZE

UP TO 4 FT.

4 TO 7 FT.

7 TO 10 FT.

10 TO 13 FT.

13 TO 16 FT.

16 TO 19 FT.

19 TO 22 FT.

22 TO 28 FT.

0 - 20 14 12 12 10 10 8 8 8 20 - 35 12 10 8 8 6 6 6 4 35 - 50 10 8 8 6 6 4 4 4

12 VOLT 50 - 65 8 8 6 4 4 4 4 2 65 - 85 6 6 4 4 2 2 2 0 85 - 105 6 6 4 2 2 2 2 0

105 - 125 4 4 4 2 2 0 0 0 125 - 150 2 2 2 2 0 0 0 00

MAXIMUM DIFFERENCE BETWEEN BATTERY VOLTAGE AND ALTERNATOR VOLTAGE IS 0.5 VOLT FOR 12 VOLT SYSTEMS AT FULL RATED OUTPUT.

MAXIMUM VOLTAGE DROP IN THE SENSING (#2-TERMINAL) LEAD MUST NOT EXCEED 0.2 VOLT FOR 12 VOLT 3-WIRE SYSTEMS.

CABLE GAUGE SIZE CALCULATION ABOVE TAKES INTO ACCOUNT TERMINAL CONNECTION RESISTANCE.

NOTE: WHEN AN INSULATED (NO FRAME GROUND) CHARGING SYSTEM IS INSTALLED, LENGTH OF RETURN CIRCUIT MUST BE INCLUDED TO OBTAIN TOTAL CIRCUIT LENGTH TO DETERMINE PROPER WIRE SIZE.

100 2008


2. Inspection Procedures:

g. Load Test (Optional)

Perform battery load test on battery or batteries to check condition. Check battery or batteries for proper type and load rating.


Battery cable length or battery mounting restricts access to battery or batteries for servicing (repair).

CHART 10

BATTERY TEST

REMOVE SURFACE-CHARGE: Discharge at 300 amps for 15 seconds.

Check for blue haze or smoke.

TEST Measure electrolyte temperature. Discharge at

1/2 the CCA rating of the battery for 15 seconds. Battery voltage must not drop below the listed

values during the 15 second test. Degrees in F Min.Voltage

70 or over 9.6 9.5 9.4 9.3

60 9.1 50 8.9 40 8.7 30 0 8.5 20 10

Out of Service if:

Battery or batteries is of insufficient CCA rating.

Battery fails load test (see Chart 10, this page).

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C. ENGINE COMPARTMENT 3. Fluid Levels and Conditions


a. Brake Fluid

Check brake fluid and brake power-assist Level of brake fluid in either side of master hydraulic fluid (if equipped) for level and cylinder reservoir is lower than 1/4 inch from condition. top or below “Add” mark (if equipped).

Brake fluid or power-assist fluid shows evidence of excessive water, oil, or dirt contamination.

Brake power-assist hydraulic fluid is below cold “Add” mark.

b. Power Steering Fluid

Check power steering fluid level and Power steering fluid shows evidence of condition. excessive water, oil, or dirt contamination.

Power steering fluid is below cold “Add” mark.

No oil is observed on dipstick. c. Oil

Check level and condition of oil. Engine oil is below “Add” mark (repair). There is evidence of fuel or water contamination in the oil.

Dipstick is missing. (Continued on Next Page)

102 2008



d. Transmission Fluid

Check level and condition of transmission Transmission fluid is below “Add” mark, or Transmission fluid is not present on dipstick. fluid. the wrong dipstick is installed (repair).

Transmission fluid shows evidence of Transmission fluid is above the full mark excessive dirt contamination (repair). (overfilled).

Transmission fluid shows need of servicing Transmission fluid shows evidence of engine (discoloration and/or burnt smell) (repair). coolant contamination.

Dipstick is missing or broken.

e. Windshield Washer Fluid

Check windshield washer fluid level. Reservoir level is low (note).

Windshield washer does not spray windshield (repair).


103 2008



f. Coolant

Check engine coolant level, condition, and freeze protection.

NOTE: Follow manufacturer’s recommendations for checking coolant condition, PH, and additive package.

Coolant level in radiator or reservoir is low (repair).

Coolant shows evidence of excessive oil, dirt contamination, or rust and corrosion (repair).

Coolant freeze/boil protection is inadequate (acceptable freeze protection - 20°F or lower). (See Chart 11, page 105; repair).

Coolant pH level is too high or too low (repair).

Coolant additive package deteriorated (repair).

Coolant cannot be seen in reservoir or in radiator tank with cap removed.

104 2008

CHART 11

105 2008

C. ENGINE COMPARTMENT 4. Belts and All Hoses


a. Belt(s)

1) Tightness

Visually and physically check all drive belts for proper tension. If available,use a tension gauge (see Figure 9, page 108). If a gauge is not available, use a ruler to measure the deflection of the belt(s) up and down at the widest point between the drive and driven pulley(s) (see Figure 10, page 108).

Any belt exceeds tension reading recommended by manufacturer, if a tension gauge is used (See Figure 9, page 108; repair).

Using ruler method, any belt has less than 1/2 inch deflection (too tight) when firm pressure is applied (See Figure 10, page 108; repair).

Any belt tensioner (automatic or manual) does not apply proper tension to belt.

Tension on any belt is too loose (based on specifications of type tension gauge used).

Tension of any belt (using ruler method) is too loose when firm pressure is applied (greater than 3/4 inch deflection).

Condition 2)

Visually inspect belt(s) for presence, glazing, oil contamination, dry rotting, cuts, and separation of plies. Check belts for twisting or distortion.

Any belt is glazed (note). Any belt is missing, oil saturated, dry-rotted, cut, or plies of belt(s) are separated.

Any belt is twisted or distorted.

3) Routing

Visually inspect belt(s) for rubbing or contact with objects other than pulleys and for correct routing.

Any belt is making contact with objects other than pulley(s).

Any belt is routed incorrectly.


106 2008


4)


Belt Alignment

Visually inspect belts for alignment.

proper


Any belt is not correctly aligned (note).


Out of Service if:

Belt misalignment is excessive and could result in failure.

107 2008

CHECKING BELT TENSION AFTER TIGHTENING

FIGURE 9 - Checking Belt Tension FIGURE 10 - Measuring Belt Tension Gauge Method Rule Method

108 2008



b. Hose(s)

1) Clamp(s) and Connections

Visually and physically check that Any hose connection or clamp is loose or is Any hose connection or clamp is stripped or hose connections or clamp(s) are over-tightened to the point of damaging the damaged. tight. hose (repair).

NOTE: References to hoses include all types of hoses located in the engine compartment, including power steering, coolant, air compressor intake, vacuum, brake hydraulic assist, engine oil, and transmission hoses.

Condition 2)

Visually inspect all hoses for cuts, Any hose is cut, abraded, worn, oil saturated, abrasions and wear, oil saturation, dry-rotted, or “ballooned” to the point that dry rotting, and “ballooning.” failure is imminent.

3) Routing

Visually inspect routing and Any hose is misrouted or unsecured so that Any hose is misrouted or unsecured so that securement of all hoses. heat damage, abrasion, or cuts could cause heat damage, abrasion, or cuts could cause

long-term failure (repair). imminent failure.

109 2008

C. ENGINE COMPARTMENT 5. Accessory Mounting and Condition


a. Air Cleaner

Check air cleaner assembly, housing, lid, Any portion of air cleaner assembly or There is any air or vacuum leaks or missing piping, gasket(s), seal, and clamp(s) for mounting is loose or damaged, including or damaged components that could cause leaks, securement, and condition. Record piping, nuts, bolts or clamps, but is not dust/dirt damage to internal engine parts air filter restriction gauge measurement. causing air leaks (repair). (dusting down piston rings and cylinders). Check for presence of wing nut and seal (if equipped). There are any worn or damaged seals or

gaskets (repair). NOTE: If air leaks are suspected, inspect for dirt/dust tracking through air cleaner assembly and intake piping. This check Air filter restriction gauge is not working Air filter restriction exceeds manufacturer’s is critical for rear engine equipped buses properly (repair). specifications. or if the bus is operated in a dusty environment such as upon dirt, sand, or gravel roads.

b. Power Steering Pump Any portion of the power steering pump,

Check securement and condition of power mounting bracketry, or fastener is cracked, steering pump. loose, or missing.

Any portion of the air compressor air filter (if c. Air Compressor and Filter Air compressor air filter (if equipped) is dirty equipped), and compressor mounting

(repair). bracketry, filter cover, or fastener is cracked, Check securement and condition of air loose, or missing. compressor and filter assembly. (Continued on Next Page)

Hose from engine air cleaner to air compressor is damaged, torn, or missing.

110 2008

C. ENGINE COMPARTMENT 5. Accessory Mounting and Condition


d. Water Pump

Check condition of water pump and pulley. There is evidence of coolant seepage from Water pump is noisy, bearing is damaged, or water pump, seal, gasket surface, or weep coolant is leaking.

NOTE: See page 136 for definitions of hole (repair). fluid “seepage” and “leaks.”

Water pump fasteners are loose, damaged, Water pump and/or fan fasteners are loose, or missing (repair). damaged, or missing to the point that failure

or leaks could occur. e. Fan

Check fan blade and fan clutch assembly for Fan has any cracked, bent, or broken securement and condition. blades.

Any portion of fan mounting is loose.

Fan clutch is seized or loose. f. Alternator

Check securement and condition of Alternator is noisy (repair). Any portion of the alternator, mounting alternator assembly. bracketry, or fastener is cracked, loose, or

missing.

Alternator is not charging.

111 2008

C. ENGINE COMPARTMENT Wiring


Routing and Condition

Check routing, securement, and condition of There is any loose, damaged, or corroded There is any unsecured or poorly routed all wiring and any electrical cable in the wiring connector or terminal end (repair). wiring that could cause potential short or fire engine compartment. due to abrasion or heat damage.

Any repair has been made using improper There are any burnt wires or missing gauge wiring (repair; see Chart 12, page insulation (other than ground straps). 113).

112 2008

CHART 12

PROPER WIRING GAUGE USAGE

MAXIMUM LENGTH OF CONDUCTOR IN FEET FROM POWER SOURCE TO LOAD

SAE Wire Size 20 18 16 14 12 10

Circuit Current in

AMPS

ft ft ft ft ft ft

1 36.4 52.3 78.0 2 18.2 26.1 39.0 63.0 99.0 3 12.2 17.4 26.0 42.0 66.0 4 9.1 13.1 19.5 31.5 49.5 78.8 5 7.3 10.4 15.6 25.2 39.6 63.0 6 6.1 8.7 13.0 21.0 33.0 52.5 7 5.2 7.4 11.1 18.0 28.2 45.0 8 6.5 9.8 15.8 24.8 39.4 9 5.8 8.6 14.0 22.0 35.0

10 5.2 7.8 12.6 19.8 31.5 15 5.2 8.4 13.2 21.0 20 6.3 9.9 15.8 20 6.6 10.5

113 2008

C. ENGINE COMPARTMENT 7. Fuel System and Lines


Fuel System and Lines

Visually check the condition, operation, and There is evidence of dirt, algae, or water in a There is any unsecured, poorly routed, or securement of all fuel system components, fuel water separator (repair). loose fuel line or hose that could cause including fuel lines securement and routing in potential fire due to abrasion or heat the engine compartment. damage.

Any fuel system connection is stripped, loose, cracked, or leaking.

Any fuel system component is damaged or not mounted securely.

114 2008

C. ENGINE COMPARTMENT Radiator


a. Radiator Mounting

Check radiator assembly and mounting for Any portion of radiator or mounting system is Any portion of radiator or mounting system is securement and condition. cracked, damaged, or has loose or missing cracked, damaged, or has loose or missing

fasteners not causing leaks or failure fasteners causing leaks or failure. (repair).

b. Cap

Check condition of radiator cap and perform Radiator cap is hard or close Radiator cap is missing. pressure test. (repair). to open

Radiator cap leaks down slowly at rated Radiator cap fails pressure test. pressure (repair).

WARNING: ALWAYS USE PROPER Radiator cap is of the wrong pressure rating or is the wrong type of cap (closed/open PROCEDURES WHEN

REMOVING RADIATOR CAP. cooling system) (repair).

There is any visible damage to the pressure c. Reservoir seat or vacuum relief seat of the cap (repair).

Check coolant reservoir (including any Any portion of coolant reservoir or mounting deaeration or overflow tank) and sight glass system is cracked or damaged, is leaking, or (if equipped) for mounting and condition. has loose or missing fasteners (repair).

d. Fan Shroud

Check fan shroud for mounting and Fan shroud is missing.Any portion of fan shroud or shroudcondition. mounting is cracked, damaged, or has loose or missing fasteners (repair).

115 2008

D. UNDERNEATH BUS Front Suspension


a. Front Wheel Bearings

Inspect front wheel bearings and related components for condition and proper adjustment of bearings. With front wheels raised (wheels unloaded), grasp tire and attempt to rock wheel to check for movement. Spin tire to check for noise and condition of bearings.

NOTE: It is important to correctly identify the source of any play. To determine if the play is in wheel bearings, have an assistant fully apply brakes while rechecking play. If movement disappears with brakes applied, then play was in the wheel bearings.

b. I-Beam

Inspect I-beam axle assembly.

There is minor seepage of oil or grease around dust cover (repair).



There is dripping of oil or grease around dust covers.

Dust cover or fasteners are missing or loose.

Any noise, binding, or roughness is discovered in bearings.

Wheel bearing end play exceeds manufacturer’s specifications (maximum of .010” in and out play measured at bearing hub).

I-beam has been cut, modified, or damaged.

There is any bluing or other evidence that I-beam has been heated.

116 2008



c. King pins

Inspect king pin assemblies for condition and play as follows:

1) With front wheels raised, grasp tire at Locking pin is loose (repair). Locking pin is backing out or missing. top and bottom or, using a pry bar for leverage, attempt to move the wheel End cap O-rings or bolts are loose or missing King pin movement is more than 1/4 inch assembly in and out. (See Figure 11, (repair). measured at outside edge of tire (see Figure page 122.) 11, page 122).

NOTE: Wheel bearings must be adjusted properly (or wheel bearing play must be eliminated by locking brakes) before checking king pins.

2) Place a pry bar under wheel and lift Vertical (up and down) play in king pin tire straight up and down to assembly is greater than 0.060” (see Figure determine condition of thrust bearing. 12, page 122), and/or thrust bearing is

damaged or missing.

NOTE: If play is beyond specifications, wear may be in the king pin, axle eye, and/or king pin bushings. Vehicle should be grounded if side play at outside edge of tire is greater than 1/4 inch. Do nottighten king pin lock (if equipped) or grease king pin before inspecting king pin assembly play.


117 2008



d. Shackles

Inspect condition of shackles, spring hangers, and pinch bolts.


Any front spring shackle or hanger is cracked or broken.

Any front spring shackle or hanger has significant side wear at spring eye.

Any front spring shackle or hanger is worn, or pinch bolt is stripped or missing so that spring pin cannot be clamped tightly.

e. Spring Mounts

Inspect spring mount bracket(s) for condition and securement.

Any front spring mount is broken or cracked.

Any front spring mount-to-frame fastener is loose or missing.

Frame is cracked at any spring mounting location.


118 2008



f. Pins and Bushings

Inspect pins and bushings as follows:

Inspect front spring pins and bushings for Any spring pin assembly will not accept Total free play (up and down) of pins and wear and lubrication. Check for wearwith front axle loaded. Insert pry bar

lubrication, or zerk (grease) fitting is damaged or missing (repair).

bushings exceeds 1/4 inch (2 pin type) or 1/8 inch (1 pin type). (See Figure 13, page 122.)

between spring eye and fixed point at frame and pull down. Measure total free Inner sleeve or rubber bushing type spring play in pins and bushings (see Figure 13, pin assembly or assemblies are worn page 122). through, or rubber bushing is excessively

worn (rubber is compacted or deteriorated, resulting in free play between rubber and spring eye or inner sleeve).

g. A-Frames and Bushings

Inspect A-frames and bushings for condition Rubber bushing(s) are split, badly Rubber bushing(s) are missing. and securement. deteriorated, or badly extruded from

suspension joints (repair). Any A-frame assembly is bent, damaged, broken, or any fasteners are loose or missing.

Any A-frame, bushing, or pivot arm has more than 0.050” free play at pivot point.

Mounting of bushing assembly or assemblies are not secure.


119 2008



h. Ball Joints

Any ball joint has more than 3/32-inch axial securement, and lubrication. Inspect ball joint(s) for condition, Zerk (grease) fitting is missing or damaged,

or ball joint will not take lubrication (repair). play.

Any ball joint nut is loose or missing, or cotter pin is missing.

Ball joint to A-frame mounting is cracked or loose, or has been welded.

i. U-Bolts

Inspect spring U-bolts for condition and Any U-bolt(s) is misaligned (repair). There is rust underneath U-bolt nuts securement. indicating possibility of looseness.

Any U-bolt, seating plate, shock mount bracket, or nut is loose or missing, cracked, or stripped.

j. Shock Absorbers

There is wetness around shock body due to securement. Inspect shocks for condition and

leaking shock fluid.

Any shock mounting or fastener is loose,NOTE: See page 136 for definitions of missing, cracked, or broken.

Any shock is broken.

fluid “seepage” and “leaks.”

Any shock fails to function. (Continued on Next Page)

120 2008



k. Springs

Inspect front springs for condition, There are any loose, missing, broken, or Any spring leaf is broken, cracked, or securement, and alignment. worn spring clips (repair). missing.

Spring eye is worn or spread such that bushings are loose in spring eye.

Any coil or leaf spring has flattened, and ride Any coil spring(s) is non-OEM, broken, height is less than manufacturer’s insecurely mounted, or non-OEM blocks or specifications (repair). spacers are installed.

Either front spring saddle (if equipped) is There is any misalignment of spring leaves worn out or missing (repair). or other evidence that center pin is loose or

broken.

Rubber bumper is missing (repair). Either front coil or leaf spring is worn so that rubber frame bumper is damaged or worn due to frequent bottoming of front suspension.

Any alignment wedge is loose or damaged.

On any air bag type spring assembly, air bag l. Wheel Seals is damaged or leaking.

Check for condition and leakage. Either front wheel seal is seeping (note). Either front wheel seal is damaged or leaking.


121 2008

122 2008

D. UNDERNEATH BUS Front Brakes


a. Brake Hoses

Any front hydraulic brake flex hose or condition, securement, and routing. Inspect front brake flexible hoses for

connection is seeping or leaking fluid, or any air brake hose is leaking air pressure.

NOTE: See page 136 for definitions of fluid “seepage” and “leaks.” Any front brake flex hose is kinked,

collapsed, bulging, has damaged plies or cord, or is damaged below outer covering.

Any front brake flex hose supporting brackets are damaged or have loose fasteners.

Any front brake flex hose is rubbing on or routed against other components.

b. Lines

Inspect air and hydraulic brakes lines for Brake line bracket(s) or securement system Any brake line is bent, crimped, or damaged routing, securement, and condition. is loose or missing (repair). significantly, restricting air pressure or

hydraulic fluid. NOTE: See page 136 for definitions of

fluid “seepage” and “leaks.” Any hydraulic brake line or connection is seeping or leaking fluid, or any air brake line is leaking air pressure.


123 2008



c. Chambers

Inspect front brake chamber assemblies for securement, condition, and proper size.

d. Slacks

Inspect slack adjusters and S-cam Slack adjuster is mounted so that adjuster assemblies for wear, condition, operation, bolt is facing chamber (repair). and securement.

NOTE: See Section D.2.j., page 128, (brake adjustment) for procedure to check operation of Automatic Slack Adjusters (ASA).


Any brake line is rubbing on other components or is abraded.

Any brake line is not of OEM material, size, or type.

Any front brake chamber, mounting bracket, or hardware is cracked, bent, broken, or missing.

Any front brake chamber or mounting fastener is damaged, loose, missing, or of the wrong type.

Either front chamber is not OEM size and stroke length.

Any portion of slack adjuster or S-cam is missing, broken, cracked, or worn beyond limits.

S-cam shaft and/or S-cam bushing total wear (up and down) is greater than 0.040-inch (see Figure 14, page 129).

S-cam in and out endplay is more than 0.060-inch (see Figure 14, page 129).

124 2008



S-cam snap ring is missing.

Slack adjuster has frozen or stripped worm gear or ratchet assembly.

e. Pushrods

Inspect pushrod assemblies for condition, Any portion of pushrod assembly (locknut, securement, and alignment. pushrod, clevis and pin, or cotter pin) is

loose, missing, or damaged.

Pushrod is rubbing against body of chamber, or chamber is misaligned.

Pushrods on left and right sides are not mounted in identical (same) slack adjuster location hole (same effective slack adjuster length).

f. Linings

Inspect linings and foundation brake There is a significant difference in lining Front brake lining (riveted type shoe) is less hardware for contamination, wear, damage, than 3/16-inch thick (Q-type) or 1/4-inch (Q-and securement.

thickness between the left and right sides plus-type) above metal of shoe (shoe table) at the center of the shoe.

(repair).

For bonded type linings, front brake lining is worn to within 1/16 inch of shoe table (face of shoe).

Front brake lining is worn to within 1/16-inch of any rivet or bolt head.


125 2008



Any foundation brake assembly does not have at least one (1) lining inspection hole.

Lining is broken, cracked, or loose on shoe.

Friction surface is contaminated with oil, grease, or brake fluid.

There is any shimming material between lining and shoe.

Lining is not proper size.

Shoe platform or webbing is cracked or damaged.

There is any loose, damaged, or missing foundation brake hardware within the drum.

g. Drums

Inspect front brake drum(s) for condition and size.


There is any crack (other than heat checks) in any drum.

There is more than 0.060-inch wear in drum friction surface (inside diameter is more than 0.120-inch over original).

There is any grease, oil, or brake fluid on inside of drum.

126 2008



Drum is not mounted securely to hub, or fasteners are loose.

Drum is not centered on hub (if equipped), causing more than 0.010-inch out of round.

h. Rotors

Inspect front brake rotor(s) for mounting, Rotor mounting is not secure. thickness, and condition.

Rotor has excessive runout (beyond manufacturer’s specifications), causing a pulsating in brake pedal.

Rotor has cracks (other than heat checks) or other mechanical defects.


Rotor thickness is less than manufacturer’s specifications stamped on rotor.

Any rotor friction surface is significantly grooved or damaged.

i. Wheel Cylinders or Calipers

Inspect wheel cylinders or calipers for Any wheel cylinder or caliper dust boot is Any wheel cylinder or caliper is not securely seepage and leaks, mounting, and condition. damaged or missing (repair). mounted or has loose or missing fasteners.


127 2008




Any wheel cylinder or caliper is seeping or leaking.

j. Adjust Brakes

1) For air wedge brakes or hydraulic drum brakes, adjust front brakes at every monthly inspection as follows:

a) Brakes must be adjusted until brake drum does not turn.

There is uneven lining or pad wear, rotor or drum damage, evidence of dragging, or other evidence that any wheel cylinder or caliper may be sticking.

There is any damage or condition, which prevents proper adjustment of air wedge or hydraulic drum brakes.

b) Back off brake adjustment until there is slight drag on drum surface (0.020” clearance between lining and drum).

2) For all Manual Slack Adjuster (MSA) equipped S-cam brakes or air disk brakes, each brake chamber pushrod travel must be measured and brakes must be adjusted at every required inspection at all wheel positions (see figure 15, page 130). Push rod travel must not exceed limits shown in "Maximum stroke length at which brakes should be adjusted" column in chart 13 on page 131.


Any MSA equipped S-cam or air disk brake cannot be adjusted to bring pushrod travel within limits shown in Chart 13 on Page 131 of this manual.

128 2008



4/7/09 3) Do not adjust Automatic Slack Any ASA is damaged or malfunctioning, or

Adjuster (ASA) equipped brakes. pushrod travel exceeds the limits shown in Pushrod travel must be measured the "Maximum stroke length at which brakes and must not exceed limits shown in should be adjusted" column in Chart 13, "Maximum stroke length at which Page 131. brakes should be adjusted" column in chart 13 on page 131. If the pushrod travel measurement exceeds the limits, the foundation brakes, slack adjusters, pushrods and chambers must all be inspected and repaired or replaced if found defective. Correctly installed, and properly working Automatic Slack Adjusters should keep the brakes in adjustment throughout the life of the linings.

Figure 14

S-cam In and Out Play

S-cam Bushing Up and Down Play 129A (Rev. 4/7/09)

2008

FIGURE 15

PROCEDURE FOR MEASURING PUSH ROD TRAVEL

Brake chamber push rod travel shall not exceed those specifications relating to maximum stroke at which brakes should be readjusted. Performance of the brake push rod travel inspection should be done with the brake application air pressure in the range of 80 - 90 p.s.i. when measuring total stroke to determine proper brake adjustment. Brakes must be fully applied to conduct this test.

CAUTION: Chock wheels before commencing this inspection as vehicle emergency brake(s) must be off.

NOTE: Refer to chart 13, page 131 for maximum pushrod travel (stroke) at which brakes should be adjusted.

130 2008

CHART 13 (Dimensions in Inches)

Type Maximum Stroke

Maximum stroke with brakes adjusted

Maximum stroke at which brakes should be adjusted

6 1-5/8 1-1/4

9 1-3/4 1-3/8

12 1-3/4 1-3/8

16 2-1/4 Should be as short as possible 1-3/4

20 2-1/4 without brakes dragging 1-3/4

24 2-1/4 1-3/4

30 2-1/2 2

36 3 2-1/4

CLAMP-TYPE BRAKE CHAMBER

"LONG STROKE" CLAMP-TYPE BRAKE CHAMBER

16 2-1/2 2

20 2-1/2 2

24 2-1/2 Should be as short as possible without brakes dragging 2

24+ 3 2-1/2

30 3-3/8 2-1/2

9 2 1-5/8

12 2 1-5/8

16 2-1/2 2

20 2-1/2 Should be as short as possible 2

24 2-1/2 without brakes dragging 2

30 3 2-1/2

36 3-1/2 2-3/4

50 4 3-1/4

ROTOCHAMBER

12 1-3/8 1-3/8

16 1-1/2 1-3/4

20 1-5/8 Should be as short as possible without brakes dragging 1-3/4

24 1-3/4 1-3/4

30 1-7/8 2

AIR DISC BRAKES

131 2008

D. UNDERNEATH BUS 3. Engine/Transmission Mounts, Starter Mounting


a. Engine/Transmission Mounts

Inspect engine and transmission mounts for condition and securement.

Any mounting fasteners are loose, missing, or broken.

b. Starter Mounting

Any mount is cracked or has deteriorated rubber.

Inspect starter for securement and condition. Check for presence of heat shield (if equipped).

Heat shield (if equipped) is loose (repair). Any starter mounting bolt, stud, or nut is loose, damaged, broken, or missing.

Starter is damaged or loose.

Heat shield looseness or damage could short positive terminal to ground.

Heat shield damaged.

(if equipped) is missing or

132 2008

D. UNDERNEATH BUS Transmission


a. Transmission Bolts

Transmission is not mounted securely to fasteners for condition and securement. Inspect transmission assembly and mounting Any transmission assembly fastener(s) is

loose, missing, or damaged (repair). flywheel housing.

There is any external indication that any torque converter bolt is loose or missing.

b. Linkage

Linkage is bent, damaged, binding, or condition, and securement. Inspect transmission linkage for routing, Modulator (TV) cable or vacuum hose is

routed where it is subject to excessive heat severely misadjusted. or abrasion (note).

Any linkage hardware or fasteners are loose Any linkage hardware or fasteners are (repair). missing or linkage is damaged so as to

cause a sticking or binding condition.

Modulator (TV) cable is exposed or casing is Modulator vacuum hose is leaking or not damaged (repair). connected.

Modulator vacuum hose is deteriorated or loose (repair).

c. Lines

Any transmission line is crimped. routing, and condition.

There is any transmission line of improper

Inspect transmission lines for securement, Any transmission line(s) is unsecured (note).

type.(Continued on Next Page)

133 2008

D. UNDERNEATH BUS Transmission


Any transmission line is worn or deteriorated to the point that failure could occur, or routed subject to excessive heat or abrasion.

d. Filter

Inspect transmission external filter assembly External filter mounting is insecure or has (if equipped) for securement and condition. loose or missing fasteners (repair).

Filter canister is damaged (repair).

e. Cooler

Transmission cooler, including all hose securement and condition. Inspect transmission cooler (as equipped) for Mounting of separate transmission cooler (if

equipped) is insecure or has loose or connections, is cracked or damaged. missing fasteners (repair).

f. Clutch

1. Operation

a) Check pedal, linkage, clutch, and Cannot adjust clutch to specs. throw-out bearing for wear, slippage, and abnormal noises in

Loose nuts and bolts (repair).

Excessively noisy release bearing. the engaged and released positions.

Noisy release bearing (note).

Clutch slips, grabs, or has excessive chatter when engaging clutch.

Binding or sticking clutch linkage or return spring.

Clutch out of adjustment (repair).

Transmission is hard to shift. (Continued on Next Page)

134 2008

D.

4.

UNDERNEATH BUS Transmission


2.

b) Visually check clutch pedal pad for wear.

c) Check clutch master and slave cylinders for hydraulic seepage or leaks and operation (if equipped).

Adjustment

Check “free play” travel of the clutch pedal. This is the first easy movement of the clutch pedal and should be no more than 1-1/2-inch and no less than 3/4- inch of travel.

Worn pedal cover pad (repair).


"Free play" is out of adjustment (repair).

Missing pedal cover pad.

Master or slave cylinder is seeping, leaking, or inoperable.

Clutch slips, grabs, or chatters after adjusting “free play” travel.

No "free play" adjustments can be made.

135 2008

D. UNDERNEATH BUS Fluid Leaks

5.NOTE: Leaks and Seepage are types of fluid loss. A fluid “Leak” is defined as enough fluid loss to cause dripping fluid. Leaking fluid can also be “slung” from rotating assemblies. Fluid “Seepage” is defined as fluid loss that may cause dampness or staining, but not dripping or slung fluid.


a. Oil

Inspect for engine oil leaks at all potential locations and determine severity.

Engine oil leakage is causing deterioration of any rubber parts, such as steering linkage boots, hoses, etc. (repair).

Engine oil is dripping at any location except on exhaust system (repair).

Engine oil is dripping on any portion of exhaust system.

There is a drip shield installed to divert leaking oil from the exhaust system (repair).

b. Coolant

Inspect all potential leaks.

locations for coolant There is coolant seeping or leaking at radiator, hoses, heater core, engine oil cooler, thermostat housing, head gaskets, freeze plugs, reservoir, water pump, or other potential locations (repair).

Leakage is excessive and could result in imminent engine failure.


136 2008

D. UNDERNEATH BUS Fluid Leaks


c. Transmission

Inspect for transmission fluid leaks at all Transmission fluid is causing deterioration of potential locations and determine severity. any rubber parts, such as steering linkage

boots, hoses, etc. (repair).

Transmission fluid is seeping, or is leaking Transmission fluid is dripping on any portion NOTE: See page 136 for definitions of of exhaust system.

(repair). fluid “seepage” and “leaks.” onto anything other than the exhaust system

d. Power Steering

Inspect for power steering fluid leaks at all Power steering fluid is causing deterioration Power steering fluid is dripping. potential locations and determine severity. of any rubber parts, such as steering linkage

boots, hoses, etc. (repair). Power steering reservoir cap or dipstick is missing.

Power steering fluid is seeping (repair).

137 2008

D. UNDERNEATH BUS Fuel Tank


a. Leaks

Inspect fuel tank assembly for leaks.



There is any fuel leakage from the tank, sending unit, connections, vent, or cap, or cap is missing.

The fuel tank is cracked.

Any hose connection(s) is loose at the tank.

b. Mounting

Inspect fuel tank mounting system and barrier (if equipped) for securement and condition.

Any portion of fuel tank mounting system (including support brackets, retaining straps, and chassis frame) is missing, loose, cracked, or broken.

Any fuel tank mounting fasteners are loose or missing.

Barrier assembly (if required) is damaged, insecurely mounted, or missing.


138 2008

D. UNDERNEATH BUS Fuel Tank


c. Hoses

Inspect all fuel lines, hoses, and under-bus Any fuel line or hose is unsecured or is fuel system components for routing, routed subject to excessive heat or abrasion. securement, and condition.

Any fuel line or hose is deteriorated or damaged (including cracks or any damage NOTE: See page 136 for definitions of that may cause seepage or leaks) or clamps are loose or missing.

fluid “seepage” and “leaks.”

Any under-bus fuel system filter, water separator, or other components are insecurely mounted, cracked, or damaged.

d. Wiring

Inspect fuel tank sender unit wiring for Any wiring or connection has damaged or Any portion of sending unit wiring (including securement, routing, and condition. ground) or connections is unsecured or is

routed subject to excessive heat or abrasion. missing insulation (repair).

139 2008

D. UNDERNEATH BUS Brake Equipment


a. Brake Lines

Inspect all brake hoses, lines, and Any brake hose or line is unsecured (repair). There is any audible air leak or visible connections for routing, securement, and hydraulic brake fluid seepage or leak. condition.

Any brake line or hose is routed subject to excessive heat or abrasion.

NOTE: See page 136 for definitions of fluid “seepage” and “leaks.” Any brake line or hose is deteriorated or

damaged to the point that failure could occur NOTE: External layer weather cracking (frayed, thin wall, rubber contaminated with

only shall not be cause for oil, crimped, etc.). rejection.

Any brake line or hose connection is loose.

b. Brake Valves

Inspect all brake system valves for There are any audible air leaks or visible securement and condition. hydraulic fluid leaks or seepage from any

brake valve.

Any brake valve is not mounted securely, is cracked, or is damaged.

c. Reservoir Mounting

Inspect reservoirs (air and vacuum tanks) for Any reservoir mounting, brackets, straps or securement and condition. fasteners are cracked, loose, or missing.


140 2008

D. UNDERNEATH BUS Brake Equipment


d. Bleed Reservoirs

Safety relief valve leaks or does not release manual operation of safety relief

1) With air system fully charged, check pressure.

valve.

2) Partially open manual petcock valve on the first (wet) tank.

3) Allow to drain until any moisture There is moisture in reservoir (desiccant type There is excessive sludge or oil (water) or contamination is drained. contamination in the reservoir (more than

eight (8) fluid ounces). air dryer equipped vehicles only; repair).

Reservoir leaks due to corrosion or is cracked.

e. Antilock Brake System (ABS)

Perform a visual inspection of all ABS Wiring or other components have been Visual inspection reveals that ABS components including wiring, connectors, damaged, or are routed or located subject to component(s) are severely damaged, and controllers. missing, and/or are no longer working.

operating normally (repair). abrasion or excessive heat, but ABS is

NOTE: Wiring from ABS controller(s) to wheel speed sensor(s) that has been abraded or otherwise damaged, exposing any wire conductor or grounding sheath, may cause failure of the antilock brake system. This damage is considered “severe.”

141 2008

D. UNDERNEATH BUS Driveline


a. Driveshafts

Inspect driveshafts for condition. Any driveshaft balancing weight (if originally Any driveshaft is bent or seriously dented. equipped) is missing (repair).

There is any foreign matter wrapped around There are any cracks or other damage in driveshaft (repair). driveshaft that could cause structural failure.

Shafts are assembled out of phase (repair).

b. U-Joints

Prior to lubrication, inspect U-joints or U-joints or CV joints are dry of lubrication, or There are any missing hardware or fasteners constant velocity (CV) joints (if equipped) for zerk (grease) fitting(s) (if equipped) is in any U-joint or CV joint assembly. condition, phasing (alignment of joints), missing, clogged, or inaccessible (repair). lubrication, and presence of all hardware. Any U-joint has significant cross-shaft-to-

bearing cup play, or CV joint has significant play.

Any U-joint or CV joint shows evidence of significant rusting of bearings.

Any bearing cup is loose in yoke.

Any U-joint is cracked or broken.


142 2008



c. Yokes

Any yoke has significant play in splines. lubrication.

Dust cap on yoke is missing (repair).

Inspect driveshaft yokes for condition and Driveshaft splines are not lubricated (repair).

Any yoke is cracked or damaged.

Zerk (grease) fitting is missing or clogged (repair).

Cork washer in dust cap is missing (note).

d. Hanger Bearings

Inspect hanger bearings and rubber Hanger bearing rubber insulator is Bearing outer race is loose in insulator, or insulators for condition and securement. inner race is loose on shaft.

Hanger bearing support is misaligned

deteriorated, damaged, or oil soaked (note).

There is significant play in hanger bearing. (repair).

There is any missing or damaged hardware or fasteners in hanger bearing or support assembly.

e. Guards

Any driveshaft guard is bent or damaged Any driveshaft guard is missing, or has loose driveshaft guards. andInspect for presence condition of

(repair). or damaged mounting fasteners.


143 2008



f. Driveshaft Parking Brake

Inspect driveshaft parking brake assembly for condition, mounting, securement, and adjustment of linings, drum, linkage, and all other related hardware.

Lining is worn down to 2/32-inch from top of rivet head.

Lining is contaminated with grease or oil.

Lining is broken, cracked, or loose.

Drum is cracked or has excessive heat damage or scoring of friction surface.

Any actuating or mounting hardware or fastener is damaged, loose, or missing.

Parking brake is not adjusted per manufacturer’s specifications.

144 2008

D. UNDERNEATH BUS Rear Suspension


a. Axle Housing

Inspect axle housing for condition and Axle housing is seeping lubricant (note). Any portion of axle housing is cracked or leakage. bent.

NOTE: See page 136 for definitions of Any portion of axle housing is leaking fluid “seepage” and “leaks.” lubricant due to cracks, porous metal, or

defective weld.

There is any leakage at or around axle housing ends.

b. Vent

Inspect condition of axle housing vent. Vent cap is clogged (repair). Axle vent is not functional or is missing.

Vent hose (if originally equipped) is cracked, clogged, or missing (repair).

c. Differential

Inspect differential assembly for condition, Lubricant level is low (repair). There is no lubricant in the differential. lubricant level, and leakage.

Differential gaskets or seals are leaking Any external differential hardware or NOTE: See page 136 for definitions of (repair). fasteners are loose or missing.

fluid “seepage” and “leaks.” Differential gaskets or seals are seeping Differential pinion yoke has endplay or (note). sideplay exceeding manufacturer’s

specifications.

Pinion/yoke end nut is loose or missing. (Continued on Next Page)

145 2008



d. Springs

Inspect rear springs for condition, There are any loose, missing, broken, or Any leaf spring is broken or missing. securement, and alignment. worn spring clips (note).

Any leaf spring or air suspension ride height On any air bag type spring assembly, air bag is less than manufacturer’s specifications is damaged or leaking, or air lines and (repair). valving are damaged or leaking.

Air ride pivot pins and bushings are loose.

There is any misalignment of spring leaves or other evidence that centering pin is loose or broken.

Rubber frame bumper is missing (repair). Either rear leaf spring is worn to the point that suspension bottoming has damaged rubber frame bumper.

e. U-Bolts

Inspect spring U-bolts for condition and Any U-bolt is misaligned (repair). There is rust underneath U-bolt nuts securement. indicating possibility of looseness.

Any U-bolt, U-bolt seating plate, shock mount bracket, or nut, is loose, missing, cracked, or stripped.


146 2008



f. Shock Absorbers

securement. Inspect rear shocks for condition and


g. Shackles

Inspect rear suspension shackles, spring hangers, and hanger pinch bolts for condition and securement.


Any shock is broken.

Any shock fails to function.

Any shock mounting or fastener is loose, missing, cracked, or broken.

There is any wetness around shock body due to leaking shock fluid.

Any rear spring shackle or hanger is cracked or broken.

Any rear spring shackle or hanger is worn, or any pinch bolt is stripped or missing, preventing the spring pin from being clamped tightly.


147 2008



h. Pins and Bushings

Inspect rear spring pins and bushings for Any grease-able spring pin assembly will not Inner sleeve on rubber type spring pin wear and lubrication. See Figure 13, page accept lubrication, or Zerk (grease) fitting is assemblies is worn through, or rubber 122, for shackle type system on checking damaged or missing (repair). bushing is excessively worn (rubber is play in pins and bushings. For other types of compacted or deteriorated, resulting in free pin and bushing configurations, see play between rubber and spring eye or inner manufacturer’s service manual. sleeve).

Rear spring pin bushing (metal type bushing) is worn through.

Total free play (up and down) of pin and bushing exceeds 1/8-inch for single pin type.

On system using two pins and bushings, combined free play exceeds 1/4-inch.


148 2008



i. Hangers

Inspect hangers for mounting and condition. Any spring hanger or bracket is cracked or broken, or any mounting fastener is loose or missing.

j. Seals

Inspect rear wheel seals for condition and There is wetness or dripping of oil or grease Either rear wheel seal is damaged or leaking leakage. excessively. around axle flange (repair).

Any axle flange stud or nut is loose or NOTE: See page 136 for definitions of missing. fluid “seepage” and “leaks.”

k. Wheel Bearings

Inspect rear wheel bearings for condition and Note: Rear wheel bearing in-out play proper adjustment of bearings. should be 0.000 inches.

1) Raise rear wheels (wheels unloaded) and release parking brake.

2) Grasp tire and attempt to rock wheel There is any detectable looseness or assembly to check for movement. roughness in rear wheel bearings.

149 2008

D. UNDERNEATH BUS Rear Brakes


a. Hoses

Inspect rear brake flexible hoses for Any rear brake flex hose or connection is condition, securement, and routing. seeping or leaking fluid, or leaking air

pressure.

NOTE: See page 136 for definitions of Any rear brake flex hose is kinked, fluid “seepage” and “leaks.” collapsed, bulging, has damaged plies or

cord, or is damaged below outer covering.

Any rear brake flex hose supporting brackets are damaged or have loose fasteners.

Any rear brake flex hose is rubbing on or routed against other components.

b. Lines

Inspect air and hydraulic brake lines for Brake line bracket(s) or securement system Any brake line is bent, crimped, or damaged routing, securement, and condition. is loose or missing (repair). significantly, restricting air pressure or

hydraulic fluid.

NOTE: See page 136 for definitions of Any brake line or connection is seeping or fluid “seepage” and “leaks.” leaking hydraulic fluid, or leaking air

pressure.

Any brake line is rubbing on other components or is abraded.

Any brake line is not of OEM material, size, or type.


150 2008



c. Chambers Any rear chamber-mounting bracket or hardware is cracked, bent, broken or

Inspect rear brake chamber assemblies for missing. securement, condition, and proper size.

Any rear brake chamber or mounting fastener is damaged, loose, missing, or of the wrong type.

Either rear chamber is not OEM size and stroke length.

d. Slacks

Inspect slack adjusters and S-cam Slack adjuster is mounted so that adjuster Any portion of slack adjuster or S-cam is assemblies for wear, condition, operation, bolt is facing chamber (repair). missing, broken, cracked, or badly worn. and securement.

S-cam shaft and/or S-cam bushing total wear NOTE: See Section D.10. j., page 156, on (up and down) is greater than 0.040" (see brake adjustment for procedure to check figure 14, page 129). operation of Automatic Slack Adjusters (ASA). S-cam in and out end play is more than

0.060” (see figure 14, page 129).

S-cam snap ring is missing.

Slack adjuster has frozen or stripped worm gear or ratchet assembly.


151 2008

D. UNDERNEATH BUS 10. Rear Brakes


e. Pushrods

Inspect pushrod assemblies for condition, securement, and alignment.


Any portion of pushrod assembly (locknut, pushrod, clevis and pin, or cotter pin) is loose, missing, or damaged.

Pushrod is rubbing against body of chamber, or chamber is misaligned.

Pushrods on left and right sides are not mounted in identical (same) slack adjuster location holes (same effective slack adjuster length).


152 2008



f. Linings

Inspect linings and foundation brake hardware for contamination, wear, damage, and securement.

There is a significant difference in lining thickness between the left and right sides (repair).

Rear brake lining is less than 1/4-inch thick at center of shoe (on brake blocks with original 3/4-inch thickness).

Rear brake lining is less than 5/16-inch thick at center of shoe (on brake blocks with original 3/4-inch thickness) (repair).

Rear brake lining is worn to within 1/16-inch of any rivet or bolt head.

For bonded linings, rear brake lining is worn to within 1/16-inch of shoe table (at center of shoe).

Any foundation brake assembly does not have at least one (1) lining inspection hole.

Lining is broken, cracked, or loose on shoe.


There is any shimming material between lining and shoe.

Lining is not proper size.

Shoe platform or webbing is cracked or damaged.


There is any loose, damaged, or missing foundation brake hardware within the drum.

2008 153



g. Drums

Inspect rear brake drum(s) for condition and oversize.



Out of Service if:

There is any crack (other than heat checks) in drum.

There is more than 0.060” wear in drum friction surface (inside diameter is more than 0.120” over original).

There is any grease, oil, or brake fluid on inside of drum.

Drum is not mounted securely to hub, or fasteners are loose.

Drum is not centered on hub (if equipped), causing more than 0.010” out of round.

154 2008



h. Rotors

Inspect rear brake rotor(s) for mounting, thickness, and condition.

Rotor mounting is not secure.

Rotor has excessive runout (beyond manufacturer’s specifications), causing a pulsating in brake pedal.

Rotor has cracks (other than heat checks) or other mechanical defects.


Rotor thickness is less than manufacturer’s specifications stamped on rotor.

Any rotor friction surface is significantly grooved or damaged.

i. Wheel Cylinders or Calipers

Inspect wheel cylinder(s) or caliper(s) for seepage, leaks, mounting, and condition.

Any wheel cylinder or caliper dust boot is damaged or missing (repair).

Any wheel cylinder or caliper is not securely mounted or has loose or missing fasteners.



Any wheel cylinder or caliper is seeping or leaking.

There is uneven lining or pad wear, rotor or drum damage, evidence of dragging, or other evidence that any wheel cylinder or caliper may be sticking.

155 2008


j.

b)


Adjust Brakes

1) For air wedge brakes and hydraulic drum brakes, adjust rear brakes at every monthly inspection as follows:

a) Brakes must be adjusted until brake drum does not turn.

Back off brake adjustment until there is slight drag on drum surface 0.020" clearance between lining and drum.

2) For all Manual Slack Adjuster (MSA) equipped S-cam brakes or air disk brakes, brake chamber pushrod travel must be measured and brakes must be adjusted at every required inspection at all wheel positions (see figure 15, page 130). Push rod travel must not exceed limits shown in "Maximum stroke length at which brakes should be adjusted" column in chart 13 on page 131.



Out of Service if:

There is any damage or condition that prevents proper adjustment of brakes.

Any MSA equipped S-cam or air disk brake cannot be adjusted to bring pushrod travel within limits shown in Chart 13 on Page 131 of this manual.

156 2008



4/7/09 3) Do not adjust Automatic Slack Any ASA is damaged or malfunctioning, or

Adjuster (ASA) equipped brakes. pushrod travel exceeds the limits shown in Pushrod travel must be measured the "Maximum stroke length at which brakes and must not exceed limits shown in should be adjusted" column in Chart 13, "Maximum stroke length at which Page 131. brakes should be adjusted" column in chart 13 on page 131. If the pushrod travel measurement exceeds the limits, the foundation brakes, slack adjusters, pushrods and chambers must all be inspected and repaired or replaced if found defective. Correctly installed, and properly working Automatic Slack Adjusters should keep the brakes in adjustment throughout the life of the linings.

157A Rev. 4/7/09 2008

D. UNDERNEATH BUS 11. Body Securement and Structure


a. Body Hold-downs

Inspect for securement and condition of all body hold-downs, chassis cowl mounts, and frame pads. Body hold-downs include any J-bolt, U-bolt, or clamp type hold down used to secure body to chassis frame.

One or two body hold-downs are loose or misaligned, or there are any cracks or stripped fasteners at floor sill securement points (repair).

Padding between frame rails and floor sills is missing or grossly misaligned (repair).

Any OEM installed body hold-down or cowl mount is missing.

Three (3) or more body hold-downs are loose, misaligned, or have missing hardware.

There are three (3) or more body hold-downs with cracks or stripped nuts at floor sill securement point.

b. Floor

Inspect condition of floor structure, sills, and braces.

There are any minor cracks in floor sills or braces or in welds (repair).

There are any holes or cracks in floor sheet metal, creating an opening to the passenger compartment.

Entire cross section of any floor sill or brace is broken.

There is any broken weld or mounting of a floor sill or brace, resulting in complete separation more than one (1) foot in length.

There is any broken weld in the mounting of the bracing (K-member) at the front of the body floor (between stepwell and driver’s area).


158 2008

D. UNDERNEATH BUS 11. Body Securement and Structure


c. Outriggers

Inspect body outriggers and hardware for Any OEM installed outrigger is missing. condition and securement.

Any body outrigger is cracked or has loose or missing hardware.

d. Braces

Inspect for condition and securement of all There is any cracked brace underneath the Any bumper brace is broken, cracked, or chassis and body braces. body (repair). missing.

e. Skirts

Inspect body skirts (and luggage Any body skirt, skirt brace, or luggage compartments, if equipped) for securement compartment has cracked or broken sheet and condition. metal or mounting points (repair).

Luggage compartment door latch, hinge, or lock is sticking, damaged, or malfunctioning (repair).

f. Frame Rails

Inspect condition of chassis frame rails, There is any crack in either frame rail or any crossmembers, and all hardware attachment crossmember. points.

There is any loose or missing rivet or other fastener securing a crossmember to the frame.

159 2008

D. UNDERNEATH BUS Exhaust Systems


a. Exhaust Leaks Any exhaust junction gasket or hardware is There is any leakage that is audible or can With engine running and at operating broken or missing (repair). be felt around any portion of the exhaust temperature, inspect exhaust system for

system including manifold(s), pipe sections, leaks, condition, and securement. There is any physical damage to exhaust or any junction.system (note).

b. Mounting There is any exhaust system hanger that is There is any originally installed exhaustInspect mounting of the exhaust system. not securely mounted (repair). hanger that is missing, broken, or detached

from exhaust system or frame mounting point.Any exhaust pipe or clamp is loose (repair). Any clamp is missing.

c. Mufflers

Inspect condition of the muffler. The muffler is cracked (repair). The muffler is leaking. There is other significant physical damage to the muffler (note).

d. Tailpipe

Inspect condition of tailpipe and ensure that The tailpipe is cracked (repair). The tailpipe is leaking. it extends beyond the rear bumper and exits to the left of the left frame rail. If equipped There is other significant physical damage to The tailpipe does not extend to at least the with regenerative type exhaust system or the tailpipe (note). rear outer surface of the rear bumper, or the starting 1998, for Type D rear engine buses, tailpipe extends more than 2 inches beyond see 2008 specifications for tailpipe the rear outer surface of the rear bumper exceptions. (see Figure 16 on Page 161), or the tailpipe

does not exit to the left of the left frame rail.

160 2008

Figure 16 Tailpipe Length

Note: The end of the tailpipe (see vertical line touching rearmost point of tailpipe in illustration at left) must extend beyond the rear outer surface of the bumper, but it must not extend more than 2” beyond the rear surface of the bumper.

161 2008

D. UNDERNEATH BUS 13. Wheels and Tires


a. Tread Depth

Inspect and measure all tires for tread depth and record on inspection form.



Out of Service if:

Tread depth of any tire is less than: • Front: 4/32” • Rear: 2/32”

measured at three (3) points spaced equally around the circumference of the tire in the same major tread groove. Do not measure at wear bars. All three points must be less than limits above before tire is required to be out-of-service. Measurement shall be taken at the most worn major tread groove of the tire.

Any single point of the most worn major tread groove of any tire measures less than:

• Front: 2/32” • Rear: 1/32”

There is evidence that any recapped tire has been re-grooved.

Any front tire is recapped or re-grooved type tire.

There is evidence that any tire has been re-grooved using a procedure not approved by tire manufacturer or dealer.

162 2008



b. Pressure

With tire cold, check pressures of all tires and record on inspection form.

NOTE: Refer to Tire and Rim Association Manual for correct air pressure for your specific tire and load rating.

Pressure in any tire is lower than 20% below the maximum cold inflation pressure stated on sidewall of the tire.

Pressure in any tire is higher than 5% above the maximum cold inflation pressure stated on sidewall of the tire.

c. Damage

There is greater than 20% difference in pressure between any tires on a particular axle.

Inspect for damage to wheels and tires. There is foreign material in the tire tread that could cause damage or loss of air pressure (repair).

There are any cuts, abrasion, or other damage to tire sidewall resulting in exposed or damaged cord.

There is any evidence of separation, bulges (other than normal manufacturer bulge), or other damage within the carcass of the tire.

NOTE: Weather cracking only shall not be cause for rejection.

There are any cracks that run around the bead or sidewall of the tire.


163 2008



Retreaded tires have any separation of the tire tread from the tire carcass that could result in tire or tread failure.

Any valve cap is missing (repair). Any valve stem is damaged or misaligned so that tire cannot be filled with air.

NOTE: Refer to Tire and Rim Association Manual for correct procedures in demounting and mounting of tires and rims.

There is any damage to the lock ring assembly or lock ring groove of a multi-piece rim, including rust or corrosion that could cause the lock ring not to seal fully.

There are any cracks or breaks at the lug holes or any other part of a rim or cast spokes.

There are minor dents or bends in a rim (repair).

There are any dents or bends in a rim that could result in failure of the rim or separation of the tire from the rim.

d. Matching

Inspect for matching of tire construction, design, size, and load rating on each axle.

There is mismatching of inner and outer dual tire diameters greater than 3/8-inch.

There is any tire marked for use other than highway use.


Any tire is not of proper type, size, and minimum load rating.

164 2008



e. Alignment


All tires on an axle are not of same type (i.e., lug or rib) and size.

Any tire is below minimum load rating.

Radial and bias ply tires are intermixed on the same axle.

Inspect tires for evidence of proper Any tire is feather-edged, cupped, or has Tires/wheels are grossly misaligned, alignment. uneven tread wear (repair). affecting steering control.

Lateral run-out of any tire/rim exceeds 1/4-inch (repair).

assembly

f. Wheel Hardware

1) Inspect for presence, type, condition, and securement of all wheel hardware.

2) Check for proper spacing of rear dual wheels and tires (proper spacer width).

There is improper matching of rims and lock rings.

There is evidence of slippage of wheel assembly on cast spoke hub.

Stud holes are elongated.

Any wheel nut, stud, or clamp is loose, or there is rust or corrosion indicating possible looseness.


165 2008



3) Inspect for correct wheel color. Stud piloted and spoke wheels are to be painted black. Hub piloted wheels are to be painted National School Bus Yellow.

4) Inspect for correct wheel type.


Any wheel, nut, stud, or clamp is broken, stripped, or missing.

Any improper spacer is installed between dual wheels.

Any bus built since October 1987 is not equipped with disc type (Budd) wheels.

Wheel(s) not painted the correct color.

Stud piloted wheel is installed on a hub piloted axle or hub.

166 2008

E. LUBRICATION AND MAINTENANCE (OPTIONAL)


This section of the form is optional. It is provided for the convenience of school districts. School districts should implement their own lubrication and maintenance policies and procedures.

167 2008

F. ROAD TEST Brake Performance


a. Parking Brake

Check for proper operation of parking brake as follows:

Apply parking brake. Place automatic transmission gear selector in drive and speed up the engine to a fast idle (approximately 1,200 RPM).

Vehicleshould not move forward. Manual transmission: When engine torque is applied by partially engaging clutch in second gear, vehicle should not move forward.

b. Stopping Distance and Equalization

1) Stopping distance

The following stopping distance requirements should be met when stopping the vehicle on a level, dry, smooth, hard surface that is free from loose material, from a speed of 20 M.P.H.:

a) Decelerometer reading (feet per second per second) minimum of 14.

Vehicle moves forward.NOTE: Buses equipped with Rear Diesel Engine and Allison World Transmission should be checked at 900 R.P.M.

Decelerometer reading is close to 14, but Decelerometer reading is less than 14. within acceptable limits (repair).


168 2008

F. ROAD TEST Brake Performance


OR

b) Stopping distance (at 20 M.P.H. Stopping distance is close to, but within, Distance to stop is greater than 30 feet. from point of brake pedal acceptable limit (repair). application) maximum of 30 feet.

c) Check for tire flat spotting before Flat spotting is severe, but will not cause Flat spotting causes any tire to fail inspection and after conducting this test. tire(s) to be rejected when following (follow measuring procedures beginning on

procedures on Page 162 of this manual Page 162 of this manual). (note).

NOTE: Use of either decelerometer or stopping distance measurement is acceptable. Lockup of brakes is discouraged as it may cause extended stopping distances and tire damage (flat spotting).

2) Equalization

Check for excessive brake pulling Bus pulls, but stops within a lane 12 feet Bus pulls sharply and will not stop within a during the stopping distance test wide (repair). lane 12 feet wide. above. (Note: Pull is excessive if steering pulls sharply, and/or bus will not stop within a lane 12 feet wide).

NOTE: Remove hands from steeringwheel while conducting the brake

equalization test..

169 2008

F. ROAD TEST 2. Engine, Transmission, Driveline


a. Engine Performance & Governor

Check for starting, color and quantity of Rough or low idle of engine (repair). Engine will not start or is difficult to start. exhaust smoke, proper idle, stalling, missing/skipping or hesitation, performance Engine exhaust gas color indicates engine is Engine will not shut down. when accelerating, and shutdown of engine. in poor mechanical condition (heavy black,

blue, or white smoke) (repair). Engine stalls.

There is hesitation upon acceleration.

Engine is misfiring.

Acceleration performance is poor.

b. Shifting

1) Automatic Transmission

Check operation of shifter and There is excessively rough up and down transmission. shifting or hard shifts.

Transmission will not shift up and down through all gears.

Transmission is slipping or noisy.

Shift points are not within manufacturer’s specifications.


170 2008

F. ROAD TEST 2. Engine, Transmission, Driveline

2)


Manual Transmission

Check operation of clutch, shifting, and transmission.


Clutch engagement is rough or noisy (repair).

Transmission is hard to shift (repair).

Clutch pedal travel has less than one inch free play (repair).

Out of Service if:

Clutch does not engage or is slipping.

Transmission jumps out of gear.

171 2008

F. ROAD TEST Steering & Handling


a. Free Play

Check for free play in steering. There is excessive wandering or shimmy due to free play in steering.

Bus wanders and requires excessive steering correction or effort to maintain straight-ahead driving.

b. Power Assist

Check power steering assist effort when There is no power assist. turning to the left or right.

Bus is hard to turn to the left or right.

There is jerking in the steering wheel when turning to the left or right.

c. Turning Radius

Check and compare the left and right turning There is a minor difference in the left and There is a significant difference in the left radius. right turning radius (repair). and right turning radius of the bus.


172 2008

F. ROAD TEST Steering & Handling


d. Steering Column

Check up and down movement of steering Up and down movement is greater than one column. inch.

e. Tracking

Check vehicle steering recovery from left and There is poor recovery on turns (repair). There is no recovery on turns. right turns, wander on rough or crowned roads, tracking and pulling when driving Bus does not track properly (front and rear straight ahead (not when stopping). wheels are not in line).

There is minor pulling in the steering (repair). Bus wanders and requires excessive steering correction or effort to maintain straight-ahead driving.

173 2008

Documents

A. INSIDE BUS 10. Dome & Stepwell Lights Inspection Procedures